Mother Dairy Delhi

INDEX
1. Introduction to industrial training, Purpose and objective of training

2. Introduction to Mother Dairy.
3. Ice Cream - Definition, Composition
4. Process of Manufacturing – Flow Diagram
5. Ingredients and Properties of making ice cream.
6. Details of machinery used in ice cream manufacturing.
7. Type of Mix.
8. Varieties of ice Cream.
9. Packaging Material
10. Storage
11. Equipment Maintenance
12. Hygienic Maintenance
13. Cleaning & Sanitization.
14. CIP
15. Quality Assurance
16. Judging and grading of ice Cream
17. Engineering Section
i. Water
ii. Boiler
iii. Refrigeration
iv. Compressed Air
v. Soft Water
vi. Electricity
NATIONAL DAIRY DEVELOPMENT BOARD (NDDB)
The National Dairy Development Board (NDDB) was designed in 1969 on Anand
Dairy Cooperative outlines of creating district cooperative of milk producers at village
level which aim at collection of whatever amount of milk they produce and payment to
them according to the quality of milk they supply. Then this milk is processed and
supplied to the people at metropolitans and other cities at nominal charges.
For about 5 yr., NDDB was dormant till the time they received presents of Whole
Milk Powder and Butter Oil from European Union and came into action with the help of
Indian Dairy cooperation.
Operation flood was started in 1970 under the guidance of Dr. Kurein, Chairperson
NDDB, Anand and Mr. Jamnadas Patel in Khera, Gujrat. The objectives of Operation
Flood are:
 To buy the milk from the farmers and villagers as much milk as they
could supply at reasonable prices and keep the price of milk stable whole year.
 To operate, procure, process and market milk and milk products.
 Production of good milk after its qualitative and quantitative

estimation.
 System to eliminate middleman.
 Providing technical inputs and services to yield of milch animals.
 Organizing an efficient transport system to collect milk from

villagers.
 Set up of balancing dairies and storage system to convert excess milk

to milk powder and butter oil.
 Train personnel to plan and manage the system as well as operate the
services described.
 To meet out these objectives, NDDB started dairy plants all over
India and Mother Dairy was one of them. It was set up in 4 major cities at Delhi,
Mumbai, Chennai and Kolkatta.
Operation flood was a major dairy development program. Funds were generated by
the sale of dairy commodities donated by the World Food Program (FAO-UN) which
assisted project to carry out its mission.
This included establishing dairy cooperatives in rural milk sheds, setting of animal
husbandry units, constructing modern dairies in cities, organizing storage and long distance
transportation and project planning with manpower development. The first phase of
operation flood was completed in 1979, followed by second phase (1979-1988), assisted by
European Economic Community. It’s third phase ended in 1996.
MOTHER DAIRY
PROFILE
Mother Dairy was set up under the operation flood project on second December 1974.
It is equipped with latest technology. Products are prepared as per the PFA standards.
The dairy was established on behalf of the Govt. of India, Ministry of Agriculture
(Dept. of Animal Husbandry and Daring). Mother Dairy is being managed by NDDB as a
subsidiary unit retaining its independent character.
For the purpose of managing the dairy NDDB appoints managing committee. All the
policy matters decided by the management committee but the execution of all the policy
decision and management of dairy rests with General Manager.
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:
• We maintain a vibrant work environment that encourages excellence.

• We empower our people that lead to continuous improvements in our
processes and systems.
• We choose such processes that ensure quality at competitive price
while protecting the environment, in which we work and live.
• 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.
ENVIRONMENTAL POLICY
We are committed to be a leader in Dairy Industry in India by being a benchmark

in environment protection.
We shall continue to improve our environmental performance by :-
• Adopting processes, procedures and systems for

clean production, pollution prevention and continual
improvements in all our activities.
• Optimizing resource utilization including energy
and water.
• Complying with applicable environmental
regulations and legislation.
• Continuing distribution of milk through
environment friendly vending systems.
• Maintain green environment through
horticultural activities.
• We pledge ourselves towards providing quality
and safe products under clean and hygienic environment.
Mother Dairy also have HACCP certification as per ISO 15000 : 1998
National Accreditation Board For Testing And Calibration Laboratories (NABL),

MDTL, Delhi has been accredited to Mother Dairy on the basis of its compliance to NABL –
criteria which are based on Chemical Testing Discipline. This accreditation is valid for a
period of 3 years.
PRODUCTS
NDDB has also set up an oil storage unit by the name of edible oil tank farm (EOTF)
in this area which has a capacity to store 50000 MT TONNES of mustard oil. Adjoining this,
is also an oil lab notified by the govt. of India that do the job of testing of oil at the time of
purchase and dispatch. It aims at providing the farmers the nominal charges for their oil
produce according to its quality and to prevent hoarding of oil by private people.
Mother Dairy has also set up an ice cream plant (ICP) about 5 years back. Through
ICP Mother Dairy markets the ice cream in and around Delhi at nominal charges and in
varied flavors. Mother Dairy also markets Safal frozen vegetables, Verka, Parag, etc.
Mother Dairy has obtained the International std. Certificate issued by International
Organizations of Standards (ISO) for its 23 years service, it’s the first in Indian food sector to
receive it.
MOTHER DAIRY VISION:
With total commitment and teamwork, we at Mother Dairy shall strive to delight our
customers with quality products and services.
We shall create an environment where employees feel happy to work.
Through innovation, consistent learning and continuous improvement, we shall achieve

sustained growth and excellence and provide remunerative returns to farmers and other
stakeholders.
MOTHER DAIRY MISSION:
“We are the market leader in fluid milk in Delhi. Our mission is to retain the leadership
and further serve our customers in and around Delhi by providing quality milk and select
dairy and food products.
We shall strive to delight our customers by providing regular and timely services at
convenient points under clean and hygienic conditions, with a product mix for different
income segment. We shall create an environment of commitment and teamwork where
employees feel happy to work.
By innovation, continuous improvement, training and development and most efficient use of
resources we shall achieve consistent and sustained growth and provide remunerative returns
to farmers and other stakeholders.”
Mother Dairy has received the ISO 9002 certificate in 1994 for the quality of its food
products.
FUNDAMENTAL KNOWLEDGE OF MILK
Milk is the secretion derived after complete milking of healthy milch animal,
excluding that obtained within 15 days before or after 10 days of calving.
COMPOSITION OF MILK
1. 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.
2. Proteins
Protein are 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 consist of Casein, Lactoglobulin and Lactoalbumin. It is in
colloidal state. Casein is only found in milk. It is easily coagulated by heat
treatment.
3. 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.
4. 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.
5. 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 affect the nutritive value.
6. 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.
7. 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 colour of milk. The
other two are Xanthophylls and riboflavin. Carotene also acts as an anti oxidant
and as a source of Vitamin A.
8. Milk Enzymes
The important milk enzymes and their specific action are as follows:
- Anise (diasterase) Starch

- Lipase Fat splitting, leads to rancid flavour
- Phosphatase It is capable of splitting certain phosphoric
esters.
- Protease It is capable of splitting proteins.
- Catalase 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 B-complex(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 calcium—one 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.
STEPS IN ICE CREAM MANUFACTURE
Making the mix:
In order to make good ice cream, the milk products and other ingredients must
first be selected and combined so as to produce the desired body and a delicately
blend flavour. The selection of good, wholesome ingredients and calculation of a
satisfactory composition proceed the mixing of the ingredients in a vat, where they
can be heated to facilitate dissolving, blending and pasteurizing. The order in which
ingredients are added as follows: liquid ingredients, basically milk, are placed in the
jacketed vat provided with a power stirrer and the agitation and heating started at
once. Powder is added at 350C and sugar, emulsifier and stabilizer is added while the
liquid material as agitate. Butter is added at about 600C. The mix is agitated and
heated to 65 – 700C and then pumped to duplex filter.
Filtration
The mix is then filtered using a duplex filter in order to make the mix completely free
of extraneous matter and give the mix a smooth consistency.
Homogenization
Homogenization of the ice cream mix is essential. The main purpose of

homogenization is to make a permanent and uniform suspension of fat by reducing
the size of the fat globules to a very small diameter, preferably not more than 2
microns. Advantages of homogenization are-
• It prevents fat separation during ageing

• Produces more uniform ice cream with a smoother texture
• Improves whipping ability
• Decrease the risk of churning occurring in the freezer and
• Leads to the use of slightly less stabilizer
Here a pressure of 1500 psi at first stage and 500 psi at second stage is applied.
Pasteurization
Proper pasteurization destroys all pathogenic or disease producing bacteria, thereby

safeguarding the health of the consumer. The advantages of pasteurization are:
i) It renders the mix completely free of pathogenic bacteria
ii) It dissolves and helps to blend the ingredients of the mix
iii) It improves flavour
iv) It improves keeping quality
v) It produces a more uniform product
The pasteurization time temperature combination in the ice cream plant here is 85 + 50
C for 25 seconds.
Chilling
The mix is then chilled to about 70C to facilitate ageing and after which it is pumped
over to ageing vat.
Aging the mix
After cooling the mix the mix is pumped to ageing tanks and it should held in ageing
tanks until used. Ageing refers to holding the mix at a low temperature for a definite
time before freezing. Ageing produces the following results.
i) It improves the body and texture of ice cream

ii) Improves whipping capacity of the mix
iii) Increased maximum overrun
iv) Increases melting resistance
The purpose of this step is to allow hydrocolloids to swell, the casein to become
hydrated, the viscosity to increase, the texture to become finer, to increase the
resistance to melting, the whip ability to improve, fats to crystallize out and aroma to
develop uniformity throughout.
Freezing
Freezing of the mix is one of the most important operations in the making of ice
cream. The freezing process may be divided into two parts.
a) The mix is quickly frozen in the freezer while being agitated to incorporate air in
such a way as to produce and control formation of small ice crystals so necessary
to give smoothens in body and texture and
b) When ice cream is partially frozen, it is drawn from the freezer into packages and
quickly transferred to cold storage rooms where the freezing and hardening
process is completed without agitation.
Fast freezing is necessary to obtain the desired small crystals which means that efficient
scraping off, large temperature differences, high rpm and high heat transfer coefficients are
required. The mix enters the freezer at a temperature of just above 0 C after the amount of air
necessary for the required over run has been added. The exits temperatures are
-3.50C to -70 C depending on the required consistency of the ice cream, which in turn depends
on the subsequent requirements.
Process of Manufacturing
Selection of Ingredients
Toned Milk
SMP
Whey Protein Concentrate
Sugar
Stabilizer
White Butter
Figuring the mix
Fat
Protein
Stabilizer
Sugar
Making the mix

mix transfer pump
Duplex Filter
Homogenization of mix
I stage 1500PSI
II stage 500PSI
Mix Heater
Inlet temp. 65 – 700C
Outlet temp. 85 ± 50C
FDV
(if not past. Properly then mix is send to
making the mix.)
Holding tube
25 sec.
Chiller
Inlet temp. 85+-5 0C, outlet temp. <9 0C.
Ageing
At < 90C for 4 to 6 hours.
Flavour tank
Continuous Freezer
At -4 to -5 0C.
Fruit Feeder machine
Packaging & Storage( at -25 to -50C)
Preparation of Mix
Milk
Preheated (35 to 40OC).
Add SMP
At 40 OC, add whey protein concentrate
Heating (65 to 70 OC)
Add stabilizer and Emulsifier
Add Sugar
After dissolved the sugar add white butter.
Recirculation
Mix
Preparation of Kulfi mix
Ingredients:
o Milk
o SMP
o White Butter
o Stabilizer
o Whey Protein Concentrate
o Sugar
Flow Diagram of kulfi mix
Milk
Preheated (35 to 40OC).
Add SMP
At 40 OC, add whey protein concentrate
Add Sugar
After dissolved the sugar add white butter.

Heated to 100 +-5 OC for developing brown colour.
Kulfi Mix.
Mix transfer Pump
Duplex Filter
Homogenizer
I 1500PSI
II 500PSI
Mix Heater
Holding tube
Chiller
Inlet 85+-5 OC,
Outlet <20 OC.
Ageing tank
<9 OC for 4 to 6 hours).
Temp. of ageing tank 7+-2 OC, chilled
water 0 to 1 OC, soft water 20 OC.
Flavour tank
Continuous Freezer (-4 to -5 OC)
Fruit Feeder Machine
Packaging
Storage (-25+- 5oC)
MOTHER DAIRY - ICE CREAM PLANT

SPECIFICATION
 Temperature of Ageing tank: 7±20C.

 Chilled Water: 0 to 10C.
 Soft Water: 200C.
 Mix Preparation Vat: 3

Capacity: 1000liters
 Duplex Filter: 2
 Ageing Tank No.1

Year of Manufacturing: 1993
 Ageing Tank No.2

 Ageing tank No. 3

Grasim Industries Ltd.
Engg Development Division
Birlagram – Nagda India
Equipment CR&ST
Capacity: 2KL
S.No.: 910101
Year of manufacturing: 1992

Grasim Industries Ltd.
Engg Development Division
Birlagram – Nagda India
Equipment CR&ST
Capacity: 2KL
S.No.: 910102
 Raw milk Tank

Capacity: 5000 liters

Indian Dairy machinery Company Limited
Vithal Udyognagar – 388121
Job No. 2224/3
Types: Syrup storage tank
Capacity: 1000 liters.

Indian Dairy machinery Company Limited
Job No. 2224/2

Job No. 2224/1
 Ageing Tank No. 8

Industrial Aiders
90 & 92, HSIDC Kundli – 131028
Distt – Sonepat ( Haryana)
Name: Ice Cream Mix Ageing Tank
Capacity 5000 liters
 Ageing Tank No. 9

Industrial Aiders
90 & 92, HSIDC Kundli – 131028
Distt – Sonepat ( Haryana)
Name: Ice Cream Mix Ageing Tank
Capacity 5000 liters
 Raw milk chiller
HMT Ltd. (Auranganad India)
Type: CM4402
M/C: 3719
 HP Homogenizer
Talia
FBF Italia BRL
Via A Frank 10
49044 Stradella di callecchic
Parma – Itlay
Machine type: TS3
Capacity: 2000LPH
Working Pressure: 210bar
Installed power: 16KW
Supply Voltage: 415V
Serial No.: 98050665
Manufacturing Year 1998
Weight: 700kg.
 Homogenizer
Capacity: 1000kg (old)
(Alfa laval)
Alfa laval India ltd.
DA PODI
Bombay, pune road, Pune – 411012
Machine type: OMO-1000

Serial No.:911000001
 Electrical Data
Volts: 415
Hz: 50
Rh: 3
Total installed Power: 7.5KW.
 Mix Heater
Alfa laval
Plate Heat Exchanger type: P13 HRB.
S.No.30101-61-637
Max. Work Temperature:
Max. Working Pressure: 6kg/cm2.
Manufactured in India.
 Mix Chiller
Alfa laval
Plate Heat Exchanger type: P13 HRB.
S.No.30101-61-637
Max. Work Temperature:
Max. Working Pressure: 6kg/cm2.
Manufactured in India.
 Butter Melting Kettle:

Balance tank:
Job No.: 2404
Type: Balance tank
Capacity: 100liter
 Cane syrup tank:

Industrial Aiders:
90&92 HSIDC Kundli
Distt – Sonepath (Harayana) 131028
Name: Melting Vat.
Year of Manufactureing: 1997
Working Pressure: 3kg/cm2.
Test pressure: 4.5kg/cm2.
 Cone Chocobar tank No. 2

cIndustrial Aiders:
90&92 HSIDC Kundli
Distt – Sonepath (Harayana) 131028
Name: Melting Vat.
Year of Manufactureing: 1997
Test pressure: 4.5kg/cm2.
 Chocolate tank No.:1

India Dairy machinery Company limited.
Vithal Udyognagar 388121
Job No.: 2224
Type: Chocolate melt tank
Year of manufactureing: 1998
Capacity: 500liter
 Flavour tank No. 1

India Dairy machinery Company
Job No.:699
Type: Flavour Mixing Tank.

Job No.:7014
Job No.:700

Job No.:2224

Job No.:2224/2

Job No.:2224/1

Industrial Aidess
90492 HSIDC Kundli – 131028
Distt. Sonepat (Harayana)

Industrial Aidess

Industrial Aidess
 Freezer no. 1 (Line No. 1)

Alfa laval
Gelmark 600
Flow rate: 600LPH
Alfa laval (India) Limited, Dapodi
Bombay Pune Road, Pun – 411012
Machine type: Gelmark 600
Electrial Data
Volts: 415
Hz: 50
Ph:3

Alfa laval
Gelmark 600
Flow rate: 600LPH
Electrial Data
Volts: 415
Hz: 50
Ph:3

Alfa laval
Gelmark
Flow rate1 60LPH
Electrial Data
Volts: 415
Hz: 50
Ph:3
 Freezer no. 5
Catta 27
40056 Crespelland(BO) itlay via Della Solid Arieta.
Modeled – Frzk 300AC.
Matricola – 274606002, 27460600
Anno Di Costruzione – 1998
Voltagigo: 415 Volts.
Fasi:3
Hz: 50
Potenza installata: 12KW, 34Amp
Refregerante: Tipo R22, 6 kg.
 Freezer no. 6 Line No. 10

Catta 27
Matricola – 258800005
Fasi:3
Hz: 50
Refregerante: Tipo R22, 8kg..
 Freezer no. 7
Catta 27
Fasi:3
Hz: 50
Refregerante: Tipo R22, 8kg.
 Freezer no. 8
Catta 27
Fasi:3
Hz: 50
Refregerante: Tipo R22, 6 kg.
 Freezer no. 9
Catta 27
Fasi:3
Hz: 50
Refregerante: Tipo R22, 6kg.

Catta 27
Fasi:3
Hz: 50
Refregerante: Tipo R22, 3.5 kg.

Catta 27
Matricola – 25840014102
Fasi:3
Hz: 50
Refregerante: Tipo R22, 3.5kg.

Constuttore manufacture
Fabric ant Bauer
Sidam
Indirizzo address adresse adresse
Via Fabio Filiz 37
20032 Cormani(mi) - Itlay
Modeled – Freezer KF75/1DE
Matricola – 8.810111
 Compressor:
Make: DORIN
Model: 750 CS/C2
Ph: 3
Serial No.: 980301760
Pressure max. 25 bar.
Prot: Thermistors PTC.
 Air Filter:
Danfoss
Eliminator
Made in Maxico
Liquid Line
Filter Drier
DCL 163
No.: 023z0009
Volts: 0.171 L Net 5.7802.
 Walzer No.: 1
Model No.: Walzer k80 NASTRO
Matricola: 43140014101
Anno Di Corstruzione: 2000
Voltaggio: V 380 Fasi 3, 50Hz.
Polfriza: installata KW Amp.
Refrigerant: NH3
Walzer pressure: 4 to 6 kg/cm2.
Temperature (Freezer): -25oC.
Defrosting Temperature: 15oC.
Chocolate temperature: 30 to 40oC.
Semi solid stare: -5 to -10oC.
Parts:
1. Chocolate Coating tank.
2. Filling Doser – 2.
3. Filling Doser – 1
4. Cnetre Filling. (Heating thermostate0
5. Stick inserter.
6. Solution sucker (For washing).
7. Pincer (Lifter & Droping)
8. Conveyeor
9. Candy Pusher.
10. Wrapping machine
11. no. of Molds: 1500x8 = 12000
12. Candy Speed: 150/min. (9000 candy/hour).
No. of molds: 12000 = 150x8x10

Speed: 130 Canddy/min. = 7800 Candy/hour.
 Automatic Candy Line:

Model : Walzer k80 (10 Row)
Make: Catta 27
Air Pressure Required: 6kg/cm2.
Total Power Required = 22KW.
Refrigerant – Ammonia (HN3).
Intermediate Coolant: CaCl2.
Evaporatuibe Temperatue: -38oC.
Coopling Load: 70000/Kcal nr.
Air Consumption: 90KLPH.
Speed: 150 Candy/min. = 9000 Candy/hour.
 Cone filling Machine (50ml)

Manufacturers: PWS Engineers Private Limited
PB No.: 62 Anand – Sujetra Rod.
Ananad – 388001
Gujrat(India)
Formerly: The Panchal workshop
Model 10-30P50ml cone
Serial No.:052/03-04
5066331 – 0002
Parts (Work junction)

1. Spray Station
2. Cone Syrup Filler
3. Ice Cream Filler
4. Topping Cone Syrup
5. Nut Filling
6. Lid Cover
7. pressing
8. Printing
9. Unloading
10. Packaging
11. Storage
 Cone Filing Machine No.2 (100ml)
Gram Varsha Anand

The panchal Workshop
Speed 51Cone/min.
1 hour = 51x60 = 3060 cone/min.
Anand, Sorjitra Road PO Box No. 12
Anand – 388001 India.
 Cone Filling Machine (100ml)
Normal Speed = 3000 Cone/hour

Speed 44cone/min.
Manufacturers
PWS Engineers Private Limited
PB No: 62 Anand – Sojitra
Road Anand – 388001
Gujrat India
Model IC30Cone
Serial No.: 013/02-03
No. of Molds: 12
 Cup Filling Machine No. 1 (100ml)

Cream Varsha Anand
The Panchal Workshop
Anannd Sojitra Road
PB No. 62
Ananad – 388001 India
No. of molds: 24
Ideal Speed: 6000cup/hour
 Cup Filling machine No. 2 (100ml)

Manufacturers: PWS Engineers Provate Limited
PB No. 62
Ananad Sojitra Road Anand – 388001
Model: IC 60 1993
No. of Molds: 24
 Cup Filling Machine No. 3 (50ml)

The Panchal Workshop
Gram – Varsha AnandAnand Sojitra Road PB No. 62
Anand – 388001 India
No. of molds: 12
 ExtrusionLine:
Hardening Temperature: -36OC to -45 OC.
No. of plates: 600
In Extrusion line temperature is maintained in the hardening tunnel
around -45OC. Forced convection is evaporators are used in the hardening
tunnel. Liquid ammonia is in the tube and fan is rotating continuously back
side of the evaporator. Cool buddies ice cream are manufactured in this
machine.
Cool buddies:
Funny face, vanilla chocolate, vanilla orange, strawberry (vanilla strawberry) Rocket (Vanilla
mango), Panda (Vanilla Chocolate).
CONE SYRUP
Ingredients
 Cocoa Butter
 Deshi ghee / butter oil
 Dark Chocolate
 Milk Chocolate
PROCESS CHART
Cocoa butter
Melt
Add butter oil / desi ghee
Melt
Add Dark chocolate
Add milk chocolate
Melt
Heating (85+-2 OC)
Cone Syrup
CONE CHOCOBAR MIX.
Ingredients
 Cocoa butter
 Lecithin
 Dark chocolate
 Milk Chocolate
 Salt
PROCESS CHART
Cocoa butter
Melt
Add Lecithin
Add salt
Melt
Add dark chocolate
Add milk chocolate
Heating (85+-5 OC)

Cone Chocobar Mix.
CENTRE FILLING
Centre filling (Ready made)
Maintain the temp. (65 to 70 OC)
Filter (through SS filter)
Ready to use
Note: Fat in centre filling 46%

CHOCOLATE MIX
Milk
Preheating (35 to 40 OC)
Add SMP
At 40oC Add Whey protein concentrate
Heating to 65 OC
Add sugar
Add white butter (unsalted)
Recirculation (mixing)
Water
Maintain the temp. 65 to 70 OC)

Add black chocolate
add milk chocolate (ratio 1:2)
Maintain at 65 to 70 OC)
Blending
Recirculation
Chocolate mix
Mix transfer pump
Duplex Filter
Homogenizer(1500PSI, 500PSI)
Mix Heater(Inlet 65-70oC, Outlet 85+-5oC,
Holding Tube 25Sec
Chiller (Inlet 85+-5OC , outlet <9OC).
Aging (<9OC for 4 to 6 hours).
Flavour tank
Continuous Freezer
Fruit feeder machine
Packaging (cardboard)
Storage (-25 ±5 OC).

CANDY MIX
(orange, Mango, Lemon, Cola., mango resberry, Orange with strawberry at centre)
Ingredients
 Water
 Stabilizer and Emulsifier
 Citric Acid
 Sugar
 Glucose Syrup
PROCESS FLOW CHART
Water
Add Stabilizer and Emulsifier
Add citric acid
Add sugar ( at 70 OC)
Add glucose
Recirculation
Candy mix
Duplex Filter
(No homogenization because fat is

not present.)
Mix Heater
Inlet 65 to 70 OC,
Outlet 85 +-5 OC
Holding tube (25 sec)
Chilling (Inlet 85±50C, Outlet <90C.)
Aging tank
< 90C for 4 to 6 hours.
Walzer
Filling doser -2 (90C)
Stick Inserter ( 2 to 30C)
Freezing (-250C)
Pincer (lifting up)
Defrosting (150C)
Through conveyer
Candy Pusher
Wrapping Machine
Packaging
Storage (-250C±5OC)
CIP SYSTEM IN ICP

Specifications
Lye Solution Storage Tank:
• Tank No.1
Indian Dairy machinery Co.
Job No.: 499
Type: Lye Tank
Capacity 1000litre.
 Tank No.2
Acid Solution Storage Tank
Indian Dairy machinery Co.
Job No.: 499
Capacity 1000litre.
 Tank No.3
Hot Water Storage tank
Job No.: 499
Capacity 1000litre.
 Tank No.4
Hot Water Recuperation water storage tank.
Job No.: 499
Capacity 1000litre.
Solution Temperature Strength
Lye (NaCl) 70 to 75 OC, 1.5 – 2%
Acid( Nitric Acid) 70 to 75 OC, 15. – 2%
Hot water 85 - 90 OC
Soft water 37.4 OC
PROCESS OF CIP
Circulation of Cold water (soft)
Circulation of lye solution, 30min.
Circulation of hot water, 10min
Circulation of acid solution, 20 min
Circulation of hot water, 10 min.
Circulation of cold water.

 Smily Tank
Paasch/Silkebary
Aktieselskobet & Silkeborg
Moskinfabrikker
Silkeborg Danmark
Type: C3A
Lb Br. H-1727
Capacity: 800Liter
Date of manufacturing: 1974
 Smily No.1
Manufactured by RT
Rollatainers Limited
166 DLF Industrial Estate.
Faridabad Haryana(India)
Machine No.: 007
Type RTCY.40
 Smily No. 2
Manufactured by RT
166 DLF Industrial Estate.
Machine No.: 009
Type RTCY.40
 Smily No. 3
14/5 Mathura Road
Machine No.: 010
Type RTCY.40
Speed: 22 Candy/min = 1320 candy/hour.
Mix Transfer Pump: 4HP.

Mix Circulation Pump: 4HP.
Hot Water pump: 3.5HP
CIP Supply Pump: 5.5HP
Milk Pump: 3.5HP
Raw Milk tank Pump: 3.5HP
CIP return Pump: 5.5HP
Mix Reception pump: 200RPM
Chilled Water Tank Capacity: 100 liter.
CANDY MIX
Ingredients Required:
 Stabilizer and Emulsifier
 Liquid Glucose
 Citric Acid
 Sugar
 Water
Saffron Sauce
 Sugar
 Liquid Glucose
 Water
 Sodium Algenate
 Locust Bean Guar (LBG)
 Kesar
 Kesar elachai
 S S Yellow Colour
Cone Syrup
 Cocoa Butter
 Milk Chocomas
 Dark Chocomas
 Butter Oil
Chocolate Sauce
 Sugar
 Liquid Glucose
 Water
 Butter
 Sodium Alginate
 Cocoa Powder
 Carnval Colour
 Creamy Vanilla
PROCEDURE
Water
Preheat (35 to 40OC)
Add Cocoa Powder
Add Sodium Alginate (Mix with sugar)
Mix it with the help of plunger
Add sugar & mix it
Add white butter
Add liquid glucose
Heated to 80OC
Cooling (35 to 40OC)
Add Carnmal Colour

Add creamy vanilla
Mix it
Chocolate sauce
Chocolate sauce is used in Jamaican almond fudge ice cream.
SAFFRON PROCESSING
Ingredients
 Sugar
 Liquid glucose
 Sodium Alginate
 LBG
 Kesar
 Kesar elaichi
 SS Yellow
PROCEDURE
Water
Preheating (65+-5OC)
Add sodium alginate & LBG
Mix it
Add sugar
Add liquid glucose
Heating (80 OC)

Chilled (15 OC)
Add colour and flzvour (SS Yellow kesar elachai)
Mix it
Filter
Add kesar
Mix it with the help of plunger
Saffron extract
Temperature should be maintained below 90C before use in production.

MILK LOLLEEZ MIX
Ingredients
 Milk
 SMP
 White Butter
 Stabilizer & Emulsifier
 Whey Protein Concentrate
 Sugar
 Water
PROCEDURE
Milk
Add water
Preheating (35-40 OC)
Add SMP
Add whey protein Concentrate
Heating (70 OC)
Add Stabilizer & Emulsifier

Add sugar
Add White Butter
Recirculation
Mix transfer pump
Duplex Filter
Homogenization (I stage: 1500PSI, II Stage: 500PSI)
Mix Heater (85OC)
Holding Tube (25sec.)
Chilling (< 9OC)
Ageing
Walzer
CHOCOLATE PASTE
Ingredients
 Sugar
 Cocoa Powder
 Water
 Carameline Powder
 Cararnal Colour
PROCEDURE
Water
Preheating(45OC)
Add (cocoa Powder + sugar mix)
Heating (85OC)
Add colour & flavour (Carameline powder & Caranal colour)
Add plain mix (1 part paste : 2 parts mix)
Duplex Filter
Cooling (5 OC)
Mixing in Plain Mix
Temperature should be maintained below 90C before use in production.
EFFICIENCY OF THE MACHINE
OEE = Overall Equipment Effectiveness.
OEE = Availability x Performance Rate x Quality Rate.
 Availability should be more than 90%..

 Performance should be more than 95%.
 Quality Rate should be more than 99%.
OEE = AxPxQ = 90%x95%x99% = 85% (OEE)
Availability means how much machine works in 24 hours.

Availability = Machine working time/Total time
Performance Rate: Current Capacity of the plant / Total capacity of the plant.
Quality Rate: No. of Right products manufactured / Total No. of Products.
Bench mark: Capacity of the equipment in LPH.
FRUITS AND NUTS MANUFACTURING
Chocolate Cone 50ml:

o Weight: 9gm (empty cone)
o Con Biscuit wt. : 7gm.
o Weight of nuts and crackles: 1.6gm
o Topping weight: 3.4gm to 4gm.
o Spray Weight: 6gm
o Ice Cream Weight: 22gm.
o Temp. of cone syrup: 50OC.
o Speed of cone filling machine: 44cone/min.
Chocolate cone 100ml:

o Speed: 48cone.min = 2880cone/hour.
o Empty cone wt. 11.4gm
o Spray weight: 8gm.
o Topping weight: 6gm.
o Nut (Kaju & chocolate crackle): 3gm.
o Lid: 1gm.
o Wrapper wt: 2gm.
o Cone biscuit: 9gm
o Total weight: 78gm.
Kulfi Cone:
o Total weight: 53.8gm.
o Stick Weight: 1.2gm.
o Lid Weight: 1.2gm.
o Kulfi Cone(without lid & stick): 23.3gm.
o Empty kulfi cone weight: 5.8gm.
Kaju Kishmish (100ml cup):
Weight of kaju kishmish in 100ml cup.
Procedure:
1. Take 100ml cup of kaju kishmish ice cream.
2. Draw the ice cream in a beaker.
3. Dissolve the ice cream with the help f pipette.
4. Filter it with the help of filler cloth.
5. Nuts is taken in Petri dish.
6. Weight the dish & note down.
7. then keep the dish in hot air oven at 101+-1OC for 1 and1/2
hour.
8. Remove the dish from the hot air oven and cool it in a
desicator.
9. The weight the dish & note down.
10. Nut is takenout from the dish.
11. Weight the nuts in paper with the help of weighing
machine.
Chillz Chocolate Treat:

o Total weight: 68.3gm.
o Centre filling weight: 8gm
o Wheat crispy weight: 2.5gm. (should be 2gm)
o Toping weight: 10.5gm.(should be 12gm).
o Stick weight: 1.1gm.
o Wrapper weight: 1.4gm.
o Chocolate ice cream weight: 41.2gm.
Strawberry ice cream cone (100ml).

o Weight of rice crispy: 0.6gm.
o Topping weight: 4.3gm/6g,/
o Empty cone weight: 12gm.
o Spray weight: 11.5gm/8gn.
o Lid Weight: 1gm.
o Total weight: 78gm.
Chillz mango Bar:

o Plain Mix Temperatue: 6OC.
o Mago Pulp Temperature: 8OC.
o Wrapper Weight: 1.4gm.
o Total weight:54.9gm.
o Cup weight: 2.8gm.
o Cup + plain mix = 27.2gn.
o Cup + Mango Pulp: 54.1gm.
o Mango Pulp Coating Weight: 54.1 – 27.2= 26.9gm.
Strawberry Crush fruit weight
o Total weight (cup with ice cream): 65.4gm.
o Strawbery weight + cup weight: 6.1gm.
o Strawbery fruit weight: 6.1 – 2.9 = 3.2gm/100ml.
Keep the fruit in metal dish and then keep in hot air oven at 101+-1OC for 1.5hour. After 1.5
hours dish is taken out and weight the dish. Calculate the moisture and substrate it from the
strawberry fruit weight: 3.2 – 0.9 = 2.3gm/100ml.
Mango & Raspberry (60ml)

o Cup + Raspberry weight: 34.5gm.
o Raspberry weight: 34.5 – 3.3 = 31.2gm.
o Wrapper + stick + Mango = 32.5gm.
o Mango = 32.5 – 2.6 = 29.3gm.
Processing of Cashewnut, Pista and Badam

- Cutting in nuts and fruits cutting machine
- heating in hot air oven at 85 +/- 5OC for 11/2 hours.
- Cool to room temperature
- Sorting based on different varities of ice cream.
- Storage of low temperature.
2. Processing of Kismiss and Tutti Fruity

- Complete washing to remove any dust extraneous matter etc.
- Washing in 25 ppm chlorine solution for 5 minutes
- Remove the water completely and store in cold store
3. Processing of Litchi
- Cutting of tin using the cutting machine and transfer the contents to clean
dish
- Allow liquid glucose which is added in proportion of 20 lichi : 1 glucose is
added and allow it act for 30 minutes.
- Wash with flow of water
- Cold storage
4. Mango Pulp
- Cut the tins and transfer the contents to a clean dish.
- Add necessary amount of sugar to mango pulp andmix well for about 62 kg pulp -
19 kg. Sugar is added
- Store under 4OC until used.
5. Processing of Saffron
1) Take necessary amount of mix and dissolve it in water to make
50% concentration syrup.
2) Heat to boiling.
3) Take calculated amount of saffron which has been previously
treated to 50OC for 10 minutes, is taken and dissolved in the mix.
4) Heat it to 30 C for 15 minutes
5) Cool and filter the mixture
6) Add the saffron mixture into mix and rest saffron is grinded
and added to mix itself.
6. Processing of Strawberry
The strawberry crush in tins is first opened
- The syrup is drained and the strawberry is transferred to filter then
- Flavour and colour is added and stored in cold storage
All the fruits and nuts processing is done in one day prior to the use of that particular fruits
and nuts
FLAVOUR
S..No. Name Flavour Quantity
1 Bars Chocolate Bars 65ml
Mango Bars 65ml
Pine Apple Bar 60ml
Raspberry Bar 60ml
Mini Chocolate Bar 45ml
Chocolate Treat 75ml
Butter Scotch Treat 75ml
Mega Bar 100ml
2 Cones Chocolate 100ml
Butter Scotch 100ml
Strawberry 100ml
Mini Chocolate Bar 50ml
3 Milk Lolly Banana, Pine Apple, 35ml
Rose
4 Ice Candies Orange Candy, 60ml
Mango Candy, 60ml
Lemon Candy, 60ml
Cola Candy, 60ml
Mango Raspberry 60ml
Orange with 60ml
strawberry centre
5 Smily Orange 35ml
Cola 35ml
6 Cool Buddies Funny face 35ml
Vanilla Chocolate 35ml
Vanilla Orange 80ml
Strawberry 65ml
Rocket (Vanilla 75ml
Mango)
Panda (Vanilla 85ml
Chocolate)
7 Kulfis Badam Kulfi 60ml
Pista Kulfi 60ml
Kesar Kulfi 60ml
8 Cassatta 150ml
Vanilla Flavour
Ingredients:
o Milk and Milk Products
o Sugar
o Permitted emulsifying and stabilizing agent.
Kaju Kishmish
Ingredients:
o Sugar
o Dry fruits & Nuts.
Tutti Fruiti
Ingredients:
o Sugar
o Fruit pulp/pieces
SUNDAE MAGIC
Shahi mithai
Ingredients:
o Sugar
o Contains permitted synthetic food colours & added flavours
Kesar pista
Ingredients:
o Sugar
o Saffron extract
Chillz Chocolate
Ingredients
o Coccoa Solid
o Sugar
o Wheat creasy
o Permitted stabilizers & Emulsifying agent, Synthetic colours & added
flavour.
o Nuts – kaju & chocolate crackle.
LIC LOLEEZ
ICE CANDY
Ice Candy – mango, Raspberry, Flavour, ice Candy
Ingredients
o Water, Cane Sugar
o Liquid glucose
o Stabilizer & Emulsifier
o Contains added fruit colour & flavour.
SUNDAE MAGIC
Jamical Almorid Fudge
Chocolate Ice cream with chocolate sauce.
Ingredients
o Milk and Milk products
o Sugar
o Nuts
o Cocoa Solids Liquid
o Glucose
o Permitted Emulsifying and Stabilizing Agent
o Contains permitted synthetic food colours & added flavours.
o Cool Buddies
Panda
Ingredients
o Chocolate and Vanilla Flavour
o Ingredients:
o Sugar
o Cocoa Solids,.
o Permitted Emulsying and Stabilizing Agent
o Contains permitted synthetic food colours and added flavours
Funny Face
Ingredients
o Chocolate & Vanilla Flavours
o Ingredients:
o Milk and Milk products
o Can Sugar
o Cocoa Solids
o Permitted Emulsifying & Stabilizing Agents
o Contains permitted synthetic colours and added flavours
SUNDAE MAGIC
Coffee Excess
Ingredients
o Milk and milk Products
o Sugar
o Nuts
o Cocoa Solids
o Coffee Powder
o Liquid Glucose
o Permitted Emulsifying & Stabilising agent
o Contains permitted synthetic food colour & added flavours
o Coffee Flavoured ice cream with chocolate sauce
Strawberry Ice Cream

Ingredients
o Milk and milk products,
o Sugar,
o Permitted emulsifying & stabilizing agent,
o Contains permitted synthetic food colour and added flavour.
Choco Chips Ice Cream

Ingredients:
o Milk and Milk products,
o Cocco solids,
o Sugar,
o Permitted emulsifying and stabilizing agents,
o Contains permitted synthetic food colours and added flavoured.
Butter scotch Ice Cream

Ingredients:
o Sugar, nuts,
o Permitted emulsifying & stabilizing agents,
o Contains permitted synthetic food colors and added flavors.
FRUIT CLASSICS
Black Current Bliss

Ingredients:
o Sugar,
o Black current fruit,
o Permitted emulsifying and stabilizing agents.,
o Contains permitted synthetic food colours and added flavour.
Cool Buddies:
Vanilla & Strawberry flavoured ice cream bar:
Ingredients:
o Sugar,
o Permitted emulsifier and stabilizing agents,
o Contains permitted synthetic food colors and added flavour.
Cool buddies
Rocket
Vanilla & mango flavoured ice cream bar
Ingredients:
o Sugar,
o Mango pulp,
o Permitted emulsifier and stabilizing agent,
Cool Buddies
Vanilla & Orange ice cream being:
Ingredients:
o Cane Sugar,
Chillz Mango Bar:

Ice Cream with ice candy covering
Ingredients:
o Cane Sugar,
o Mango pulp,
o Liquid glucose,
o Citric acid,
o Permitted emulsifier and Stabilizing agent.
Chillz Raspberry Bar:

Vanilla Flavoured ice cream with Raspberry flavoured:
Ice Cnady Covering
Ingredients:
o Cane Sugar,
o Liquid Glucose,
o Fruit Pulp,
o Citric acid,
o Permitted Stabilizer and emulsifying agent.
Chillz Mega Bar:

Vanilla Flavoured ice cream with chocolate covering:
Ingredients:
o Cocoa solids,
o Cane sugar,
o Wheat crispy,
Chillz Chocolate Treat:

Chocolate ice cream with chocolate covering
Ingredients:
o Cocoa solids, sugar, wheat, crisp,
Chillz Pineapple bar:

Vanilla flavoured ice cream with pine apple flavoured ice candy covering
Ingredients:
o Cane Sugar,
o Liquid Glucose,
o Pine apple pulp,
o Citric acid,
o Permitted emulsifier and stabilizing agent.
Smily
Cola Flavour
Ingredients:
o Water,
o Cane Sugar,
o Liquid Glucose,
o Citric acid,
Smily
Orange Flavour
Ingredients:
o Water,
o Cane Sugar,
o Liquid glucose,
o Citric acid,
Lic lolleez
Milk Lolleez
Pine apple and Milk
Ingredients:
o Cane Sugar and permitted emulsifier and stabilizing agent,
Lic lolleez (milk lolleez)
Rose and Milk
Ingredients:
o Cane sugar. permitted emulsifier and stabilizing agent,
Fruit classic
Pine apple wonder (with pine apple pieces)
Ingredients:
o Sugar,
o Pine apple pulp,
o Fruit,
Chillz Strawberry Cone 100ml

Ingredients:
o Sugar,
o Wafer biscuit,
o Cocoa solids,
o Rice crispy,
o Permitted emulsifying and stabilizing agents.
Kulfies
Budam kulfi
Ingredients:
o Sugar,
o Nuts,
o Permitted,
o Emulsifying and stabilizing agent,
o Flavoured with badam.
Pista Kulfi:
Ingredients:
o Sugar,
o Nuts,
o Flavoured with Pista.
Kesar Kulfi:
Ingredients:
o Sugar,
o Nuts,
o Permitted and stabilizing agents,
o Flavoured with kesar.
Fruit Classic
Mango Marvel: With real alphorrso.
Ingredients:
o Sugar, mango pulp,
Sundae magic
Shahi mava malai
Kheer flavoured ice cream with saffron sauce:
Ingredients:
o Sugar,
o Nuts (kaju and badam),
o Saffron extract,
o Liquid glucose,
Chillz mini chocolate bar

Ingredients:
o Cocoa solids,
o Cane sugarm permitted emulsifying and stabilizing agents.
Kulfi pista
Ingredients:
o Sugar,
o Nuts,
o Permitted emulsifier and stabilizing agent.
Nuts and Fruit Room
Processing and Storage of Nuts:
Issue of nuts from store for processing
Sorting
Cutting
Roasting (85+-50C for 90min.)
Cooling in normal temperature.
Put in dry basket.
Weighment
Storage.
Processing of Kaju, Pista and badam.
1. Cutting the nuts by machine.

2. Keep the nuts in oven for (85+-5oC) at 1.5 hours.
3. After roasting cool the nuts at normal temperature (room).
4. Filter the nuts by steel mesh.
5. Grinding the nuts according to the different ice cream.
Processing of Chikki
1. Break the chikki strip in small pieces with the help of hammer.
2. Filter the chikki by steel mesh according to the different ice cream.
Processing of Kishmish & Tutti Fruiti
1. Wasing the fruits.

2. no dirt or dust should come on the surface of fruit.
3. Washing in 50ppm chlorine. Solution for 5 min.
4. Taking out remaining water.
5. Keep the fruit in cold storage for cooling.
Processing of Litichi
1. Open the tin of litichi by in cutting machine carefully.

2. Keep the fruits in liquid glucose and then drain out from water.
3. Keep the litichi in cold store for cooling.
Processing of mango pulp
1. Cutting the tin of mango pulp.

2. keep the mango pulp in clean utencils.
3. Mix the sugar according to the requirement (1kg pulp, 300gm sugar)
4. Store at 4OC till it is utilized.
Processing of kesar
1. Take the appropriate quantity of mix.

2. Dissolve in water of 250% concentrate/
3. Boil the solution.
4. Add roasted kesar at 50OC for 10min.
5. Heat it at 80OC for 15 min.
6. Cool the mixture and filter it.
7. Mix the solution in mixture and add remaining leaves after grinding.
Flow Chart
Plain mix
Kesar
Standardized
Keep in Box (1:1)
Mix
Keep in hot air oven (roasting, 50OC for 10min.)
Heated (85OC)
Mix with kesar
Boiling
Filtration
Grinding
Mix with plain mix
Storage
Strawberry
Flow Chart
Strawberry (Box)
Open the lid
Filter (Drain the syrup)

Keep the strawberry fruit in vat.
Add strawberry flavour(1kg fruit and 2 ml flavour)
Mixing
Ready for strawberry crush ice cream
Butter Scotch Crackle

50% kaju + 50% butter scotch crackle.
Mix
Ready for butter scotch ice cream

Chocolate Crackle
Chocolate crackle(5 kg)
Add cocoa butter (1kg chocolate crackle, 20gm cocoa butter)
Mixing
Add 50% of kaju(cutting roasted kaju)
Mixing
Use in Production
LECITHIN
Analysis of Lecthin
Solubility
 Soluble in Chloroform in petroleum either

 Insoluble in acetone and water.
Colour
 Brown, Light yellow to brown
Acid Value: 29.26, 35% max.
Moisture content: 0.8%, 2% max.
Description:
The material is viscous semi liquid with a characteristic odour. It is light yellow to
brown depending upon whether it is bleached or unbleached. Lecithin is obtained from egg or
edible vegetable oil seed by suitable dehydration or solvent extraction. Using food grade
solvents. It may also be obtained from animal sources.
Kesar (Saffaron)
Flow Chart
Saffaron (Stigma)
Spread in a Tray
Keeping in Oven at 500C for 10mn.

Stir in Hot milk for 5-6 min.
Strain saffaron extracted milk
Retenate (kesar)
Grind to paste
Mix with ice cream mix in flavour tank.
Black Current Processing:
Black current fruit
Sorint
Keep in vat
Washing
Filter
Washing
Filter
Washing
Filter
Add water 40 liter.
Add 25ml chlorine
Washing
Filter
Keep in box processing
QUALITY CONTROL LABORATORY

(ICP)
Solutions used in ICP laboratory.
1. Potassium Dichromate
2. Ammonia Buffer solution
3. Erichrome Black T indicator
4. N/50 EDTA
5. AgNO3 (N/10)
6. 10% K2Cr2O4 (Potassium Chromate)
7. N/10 HCl
8. Cupric Sulphate Solution
9. Potassium Sodium Tartarate.
10. Methylene blue indicator.
11. Lead Acetate
12. P. Rosolic acid solution
13. N/10 oxalic acid
14. Phenolphthalein solution
15. Potassium Chloride
16. N/10 NaOH solution
17. Phenophthalein indicator
18. Rosalic Acid.
Preparation of chemicals
1. N/50 EDTA:
Dissolve 3.72gms of EDTA in 1L of distilled water.
2. N/10 AgNO3:
Dissolve 16.9gm AgNO3 in 1L of distilled water.
3. 10% potassium chromatic:

Dissolve 10gms K2CrO4 in 1L of distilled water.
4. Neutral lead acetate:

Dissole 41gms of lead actetate in distilled water and neutralize with CH 3COOH or
NaOH (using litmus paper) anmd then dilute to 100ml.
5. Nesslers Reagent:
Mix solution A (8gm HgCl2 in 150ml of distilled water) and solution B (60gm NaOH
in 150ml distilled water). Add solution C (16gm K.I in 150ml distilled water). Make
volume to 500ml.
6. Rosalic acid solution (0.05%):

Dissolve 2.5gms of rosalic acid powder in 5 L of 60% alcohol (3L of distilled
rectified spirit and 2 liters of distilled water).
7. Sodium Hydroxide (N/10 NaOH) solution:

Dissolve 4gms of NaOH pellets in distilled water and make up he volume to 1 L.
Standardize with N//10 oxalic acid.
8. N/50 EDTA;
Dissolve 3.72gm of EDTA in 1L of distilled water.
9. N/10 AgNO3:
Dissolve 16.9gm AgNO3 in 1L of distilled water.
10. 10% Potassium Chromate:
Dissolve 10gm of Potassium Chromate in 1L f distilled water.
11. Natural Lead Acetate:

Dissolve 41gm Lead Acetate in distilled water and neutralize with CH3COOH or
NaOH (using litmus paper) & then dilute to 100ml.
12. Eriochrome Black:

Dissolve 0.5gm eriochrome black T in 100ml rectified spirit.
13. 50% Hydrochloride:

Dilute 50ml of concentrated HCl with 50ml of distilled water.
14. N/10 HCl solution:

Dilute 25ml concentrate HCl to 2.5 litre in distilled water ( 10ml concentrated HCl in
1 litre of distilled water).
15. Oxalic acid (N/10):

Dissolve 6.30gm in 1000ml of distilled water.
16. Phenolpthalein Solution (0.5%):

Dissolve 5gm phenolphthalein powder in 50% alcohol (500ml) and then add 500ml
of distilled water to make up the volume 1 Litre.
Standardization:
NaOH (0.1N):
1. Prepare a concentrated stock solution of NaOH by dissolving equal parts of

NaOH (pellets, AR grade) and water in a flask.
2. Tightly place stopper with rubber bung and allow it to stand for 3 to 4 days.
The impurities (Na2CO3 and NaHCO3) will settle down as turbid solution at the
bottom.
3. Decant the clear supernatant for standardization of either 1N or 0.1N solution.
This is standardized against 11N or 0.3N oxalic acid.
Silver Nitrate (AgNO3):
1. Prepare 0.1N solution be dissolving 17.5gm of AgNO3( eq. wt. 169.67) in the
halogen free water and dilute to volume 1Litre.
2. Store the reagent in amber colour bottle.
3. Standardize the AgNO3 solution against a solution of NaCl of known strength
by volhard method in the following manner.
4. Place on a watch glass about 5gm of NaCl (eq. wt. 58.5) and dry in an oven at
250 to 350OC for 1 to 2 hour. Cool in a desicator.
5. Weigh accurately in a treated beaker 5.85gm of the dried salt.
6. Dissolve the salt in chloride free distilled water and transfer quantitatively in 1
litre volumetric flask.
7. make up volume to the mark with halogen free distilled water.
8. Mix it well and store in reagent bottle.
9. Fill up prepared AgNO3 solution in burette.
10. Pipette 10ml of 0.1N NaCl into 150ml conical flask.
11. Add 2ml of 5% potassium chromate indicator and titrate wth NaCl solution.
12. Rotatingthe flask continuously until the addition of one drop of the AgNO3
causes the turbid yellow liquid to move towards a reddish colour (Brick red) which
persists after briskly shaking the flask.
13. Repeat the titration until concordant result are obtained.
14. Deduct from the value, the amount of AgNO3 required to produce the similar
changes of colour in a mixture of 20ml of distilled water.
15. 2mkll of indicator and produce approx. the same degree of turbidity.
EDTA
1. Dissolve 3.8gm commercial AR disodium ethylenediamine

dihydrogen tetra acetate, which has been dried at 800C for 1 hour in distilled or
deionized water and make the volume to 1 litre.
2. Mix it well. Store in polyethylene reagent bottle.
3. Standardize it against 0.01M CaCO3 or CaCl2.
4. Prepare standard Ca solution (1mLength=1gm CaCO3
mWidth=100) by weighing 1gm CaCO3 dried overnight or longer at 105oC into
500ml concialflask or beaker and adding dilute HCl through tunnel until CaCO3 is
dissolved.
5. Add 20ml water, boil to expel CO2 and cool.
6. Add few drops of mehyl red indicator and adjust colour
intermediate orange (Brownish red) with dilute NH4OH or HCl as required.
7. transfer quantitatively to 1Litre volumtrai flask and make up
the volume to the mark.
8. Shake it well and store in air tight readent bottle.
9. Rinse and then fill burrette with prepared EDTA solution.
10. pipette 25ml of standard CaCO3 solution into 250ml standard
CaCO3 solution into 250ml concial flask.
11. Add 1ml ammonia buffer and 3-4 drops of Erichrome Black T
indiactor.
12. Titrate with EDTA solution until colour changes from wine red
to dark blue with no reddish tunge remaining..
13. Calculate the molarity of EDTA (m1v1 = m2v2), if excess
follow the procedure for the standardization of NaOH.
14. After final standardization, recheck the molarity and it should
be 0.01M.
HCl
Specific gravity = 1.18 at 20OC, strength = 12N & 36% by weight.
For preparing various normal solution the eq. wt. is not used but commercial ly normal
strength (12N) is taken for calculation. The prepared solution can be standardized with
solution of anhydrous Na2CO3 using methyl orange as an indicator with orange to red end
point.
OXALIC ACID:
1. Weigh accurately 6.304 (1N) or 0.6304 (0.1N) oxalic acid (eq. wt. 63.04) which
has been previously dried at 103-105OC for 30min and cooled in desicator. Using a
clean dry weighing bottle or small beaker.
2. Add some distilled water and dissolve with the help of a glass rod.
3. Transfer the solution quantitatively (washing beaker and glass rod with distilled
water) in a 100ml volumetric flask through a funnel.
4. Make up the solution with distilled water to the mark.
5. Shake it thoroughly and store in a clean dry reagent bottle. The strength remains
unchanged for a long period.
6. take a clean burette and rinse it with little (5ml or so) . prepared sodium
hydroxide solution and clamp it vertically on a stand.
7. Pipette 10ml of oxalic acid solution in a 100 or 150ml conical flask.
8. Add 2-3 drops of phenolphthalein indicator and shake it well.
9. Titrate it with sodium hydroxide solution with shaking until permanent faint
pink colour persists.
CHEMICAL ANALYSIS OF ICE CREAM

OVER RUN
Procedure:
1. Clean and weigh the over run cup.

2. Fill the brim with ice cream mix and weigh.
3. Record the weigh of the mix.
4. Clean, Dry and weigh the over run cup.
5. Fill the brim with ice cream and scrap the top.
6. Record the weight of ice cream.
volume of ice cream of unit weight − volume of mix of unit weight

Over run % ( By Volume ) =
volume of mix of unit weight
weight of mix of unit volume − weight of ice cream of unit volume

Over run % ( By Weight ) =
weight of ice cream of unit volume
Note:
Specific gravity of Gerber Sulphuric Acid: 1.84
Specific Gravity of amyl alcohol is 0.82
Specific Gravity of plain mix is 1.1
Specific Gravity of milk lollees is 1.04
Specific Gravity of Candy mix is 1.08
Specific Gravity of Kulfi mix is 1.17
Specific Gravity of Chocolate mix 1.1
Specific Gravity of Fat is 0.93
Specific Gravity of SNF is 1.3
Determination of Sucrose
(A) Determination of Original Reducing Sugar.
1. Weigh 10gm of ice cream sample into 250ml conical flask.

2. Add 150ml water and mix thoroughly.
3. Add neutral lead acetate drop by drop with rotating gently, until no further
precipitating form.
4. Add one drop of alumin cream.
5. Mix and keep it for few minutes with occasional rotation to ensure complete
precipitation of protein.
6. Add just sufficient sodium oxalate to precipitate any excess of lead.
7. Filter through filter paper no.1 into 250ml volumetric flask.
8. Wash the precipitate with hot water.
9. Collecting all the washing in flask.
10. Cool and make up the mark.
11. Carry out titration against 10ml Fehlings solution.
Original reducing sugar(%) = (25xX)/(SxW)
Where,
X = mg invert sugar equivalent
S = ml of the dilute filtrate used for titration.
W = Weight in gm of the sample.
(B) Determination of Reducing Sugar after inversion:
1. Take 10ml diluted filtrate into a 200ml volumetric flask.

2. Add 25ml water and 10ml 6.34N HCl.
3. Invert as described in the preparation of standard dilute invert sugar
solution,
4. Carryout titration against 10ml Fehlings solution
Sucrose = (Reducing sugar after inversion – Reducing Sugar before inversion) x 0.95.
(by wt.)
The value of X can be determined by standardization of 10ml of Fehlings solution.
PACKAGING MATERIAL
GSM ( Gram Square Meter).
GSM is calculated to find the strength of the material.

Procedure:
1. Take a brick of ice cream of any size.
2. Cut it one side rectangular piece.
3. Findout the area and weight of rectangular piece.
4. Calculate the GSM.
Types of Packaging Material

CBX (Cerugated Box) Specification
1. 50ml Cones
2. 100ml cones
3. 50ml Cups
4. 100ml cups
5. Cool Boddies
6. Chillz bars
7. Chillz mega bars
8. Sundae magic/Fruit Classic
9. Milk Lolleez
10. Cassatta
11. Chillz Choco treat
12. Chillz mini chocobar
13. Chocobar or chillz chocolate bar.
14. Lic lolleez
15. Chillz treat bar
16. ulfi
17. Smily ice candy
Separator
1. 50ml cup
2. 100ml cup
3. 50ml cone
4. 100ml cone
100ml Cone
PACKAGING BREATH= 16.2 cm
MATERAILS
LENGTH= 27.2 cm HEIGHT= 10.4 cm
50ml Cones BREATH= 16.6 cm WIDTH= 63.8 gm
LENGTH= 28cm HEIGHT= 12.1 cm MRP= 216
BREATH= 14cm WIDTH= 80 gm
H= 10cm MRP=272 Sundae Magic
WIDTH= 67.1gm LENGTH= 28 cm
MRP= 140 Chillz Mega Bar BREATH= 14.2 cm
LENGTH= 18.4cm cm HEIGHT= 10.5 cm
WIDTH= 69.2 gm BREATH= 24.2 cm LENGTH= 30.9 cm
MRP= 160 HEIGHT= 8.4 cm BREATH= 14.1 cm
WIDTH= 134.9 gm HEIGHT= 13.4 cm
Lic Lolleez MRP= WIDTH= 73 gm
LENGTH= 25.5 cm MRP=140
BREATH= 16.8 cm Chillz Treat Bar
HEIGHT= 8.9 cm LENGTH= 28.4 cm Chillz Mango Bar
WIDTH= 74.5 gm BREATH= 17 cm LENGTH= 26 cm
MRP= 120 HEIGHT= 9.5 cm BREATH= 16.8 cm
WIDTH= 87.9 gm H= 9.5 cm
Chillz mini chocolate bar MRP= 384 WIDTH= 74.8 gm
LENGTH= 22.6 cm MRP= 312
BREATH= 17.3 cm Cool Buddies
HEIGHT= 8.6 cm LENGTH= 22.9 cm Smily ice Candy
WIDTH= 62.9 gm BREATH= 16.7 cm LENGTH= 25.6 cm
MRP= 240 HEIGHT= 10 cm BREATH= 16.1 cm
WIDTH= 70.2 gm HEIGHT= 8.5 cm
MRP= 120 WIDTH= 69.4 gm
MRP= 100
Cassatta
LENGTH= 21.3 cm Lic Lolleez (milk lolleez)
BREATH= 14.6 cm LENGTH= 22.1 cm
HEIGHT= 14.9 cm BREATH= 15.9 cm
Chillz Chocolate Bar WIDTH= 73.7 gm HEIGHT= 8 cm
LENGTH= 28.3 cm MRP= 240 WIDTH= 59.8 gm
BREATH= 17 cm MRP= 96
HEIGHT= 9.4 cm
WIDTH= 81.5 gm 50ml cup/50ml cone
MRP= 336 LENGTH= 23.3 cm
BREATH= 15.2 cm
Chillz Cone 100ml WIDTH= 6.8 gm
LENGTH= 27 cm
BREATH= 16.4 cm Fruit Classics 100ml Cone
HEIGHT= 12.1 cm LENGTH= 24.4 cm LENGTH= 25.1 cm
WIDTH= 80.1 gm BREATH= 24.4 cm BREATH= 16.6 cm
MRP= 272 HEIGHT= 8.4 cm HEIGHT= 8.2cm
WIDTH= 131.4 gm
Sundae magic/Fruit Classics
LENGTH= 24 cm Kulfi
CBX (CORRUGATED BOX)
Calculation of GSM of the CBX
Procedure:
1. Take different types of CBX of ice cream.

2. Cut it into rectangular pieces of each CBX of ice cream.
3. Fold the rectangular pieces and keep in water beaker.
4. After 1/2hour drawn the pieces and separate it into three different layer.
5. Keep the layer in hot air oven (101+- 1oC) till it becomes dry.
6. Draw the piece from the hot air oven.
7. Measure its dimension & weight.
8. Calculate the GSM (Gram Square Weight).
Laminate GSM
Procedure:
1. take different types of laminate of different variety.

2. Cut it into rectangular portion.
3. Measure its dimension and weigh.
4. Calculate the GSM.
Bursting Strength of Packaging material

Appratus: Bursting strength tester.
Principle: When the packaging material is pressed from both sides and pressure is applied
by liquid filled ball from bottom, it cause bursting of the material. The pressure
indicated by pressure gauge is noted.
Procedure: Tighten the packing material between the seats of the tester and press the button,
which increase the pressure and the pressure is noted from pressure gauge.
Bursting strength of Packaging material (CBX should be 4kg/cm2)
Corrugated boxes
Specification
S.No. Description Paper GSM Face Bursting strength (kg/cm2)
Influte inside
1 50ml cup 100:80:80 4.0
separator 180 -
2. 100ml cup 100:80:80 4.0

separator 180 -
3. GIC Cells 100:100:100 4.6
4. Lic Gel 100:100:100 4.6
5. Cones 100:80:80 4.0

separator 280 -
6. Cassatta 100:80:80 4.0
7. Smily 100:100:100 4.6
(Ice Candy)
8. Lic Lolly 100:100:100 4.6
9. Doodle Bar 120:100:100 4.8

(Chcocrome)
10. Doodle bar 120:100:100 4.8

Mango cream
11. Chocotreat 120:100:100 4.8
12. Joy stick 100:80:80 4
13. Mumbo Jumbo 120:100:100 4.8
14. Sundae Magic 100:80:80 4
15. Doodle Bar 100:80:80 4

Choco crème mini 4
16. Kulfi cups 100:80:80 4.0

Separator 100:100:100 -
17 Choco Fun 500ml 100:80:80 4.0
18 PP Tubes 120:120:120 0.5

Total GSM
TESTING OF MIX
Chemical test:
 Fat Percentage (Gerber Method)
 Total Solid
 Acidity (%)
 Protein Percentage (Pyne’s method)
Fat Test:
Apparatus:
Butyrometer, pipette (10ml), stopper, centrifuge, Gerber acid (90% sulphuric acid), amyl
alcohol.
Principle:
Gerber acid dissolves all the constituents other than fat and amyl alcohol reduces the surface
tension & helps in separation of the two media.
Procedure:
1. Put 10ml of Gerber Sulphuric Acid in ice cream butyrometer.
2. Pour some amount of water in the same.
3. Now put this butyrometer in cylinder on the weighing machine and set its weight to
zero.
4. Weigh 5gm of sample into ice cream butyrometer. The sample should not tuch the
walls of the ice cream butyrometer.
5. Add 2ml amyl alcohol.
6. Now pour some distilled water to make up the volume.
7. Keep this butyrometer in a centrifuge at 1400RPM for 5min.
8. Keep out from the centrifuge and note the percentage of fat
9. Divide this reading by weighing of the sample taken & multiply this value by 5, so
exact percentage fat will come out in 5gm of sample.
Fat% = (Ice-cream butyrometer reading x 5)/wt. of sample.
Protein Test by Pyne’s Method:
Apparatus:
Beaker, Pipette, Buretter
Reagent:
Phenopthalein, Saturated potassium oxalate, Formaldehyde (natural), Std. NaOH (0.1N).
Principle:
The carboxylic group of alpha amino acid cannot be accurately titrated with alkali as it result
with basic amino group to from zwitter ion that are not decomposed completely at the end
point of the decomposed completely at the end point of the reaction. The amino acids are first
neutralized with formaldehyde which black the terminal group of amino acid and can be
sharply titrated with alkali. The amount of alkali required for the purpose is proportional to
the carboxylic group of amino acid.
Procedure:
1. Wash the beaker with water, clean it with tissue paper.
2. Weigh, clean, dry an empty beaker and set its weight to zero.
3. Weigh exactly 10gm of sample into beaker.
4. Make up the volume of 50ml.
5. Add 1ml of phenopthalein indicator into the beaker. Shake it well.
6. Add 0.4ml of saturated potassium oxalate in the beaker.
7. Wait for 2 minutes.
8. Titrate the contents with Std. NaOH solution (to pink colour).
9. Now add 2ml of neutral formaldehyde.
10. Shake it and titrate against std. NaOH solution.
11. Calculate the protein percentage by the formula.
Protein percentage: 1.7x vol. reading.
Acidity Test:
Apparatus:
Beaker, Pipette, Burette
Reagent:
Phenopthalein, Std. NaOH (0.1N)
Principle:
The titrate acidity test is employed to find out the acidity of the mix prepared, which of
higher can reduce its keeping quality. The principle is the simple acid-base titration in which
phenolphthalein is used as an indicator, which gives pink colour in alkaline medium and is
Colourless in acidic media.
Procedure:
1. Wash the beaker with water, clean it with tissue paper.
2. Weigh a clean, dry and empty beaker and set its weight to zero.
3. Weigh exactly 10gm of the sample into the beaker.
4. Make up the column of 50ml by adding distilled water.
5. Add 2 to 3drops (1ml) of Phenopthalein indicator into the beaker.
6. Titrate against N/10 NaOH solution.
7. Note the reading of the burette in terms of ml of std. NaOH and utilized multiply this
value by 0.09 and divide this fraction by the weight of sample taken to get acidity of
given sample.
Percentage Acidity: 0.09x vol. reading.
Neutralization Test:
Object: To check the neutrality of the sample.
Apparatus: Pipette, test tube, rosalic acid solution in 60% ethyl alcohol.
Reagent: Rosalic acid solution in 0% ethyl alcohol.

Principle: Mix is having slightly acidic pH of 6.5 to 6.7. Rosalic acid in acidic pH gives
orange pink colour.
Procedure:
Take 1ml rosalic acid and 1ml of sample in test tube and shake well.
Petal red indicates positive test.
Slightly orangish shade: Negative test.
Phosphatase test:
Object: To test for pasteurization of the sample.

Apparatus: Pipette, Test tube.
Reagent: Phosphatase dye.
Preparation of phosphatase dye:
Base – Alkaline buffer (sodium carbonate and sodium bicarbonate).

2,3 para nitrophenyl phosphate + Orthophosphate indicator.
Phenyl group of indicator + Acid phosphatase of milk.
Yellow colour (phenyl derivative).
Principle:
On pasteurization of mix, enzyme acid phosphatase gets destroyed. If sample gives
fluorescent yellow colour with the sample, with 30 minutes of the set up, it shows that the
acid phosphatase is active and sample is not completely pasteurized.
Procedure:
1. Take 1ml of sample in test tube.
2. Add 5ml phosphatase dye and shake well.
3. Now incubate for 2 hours at 370C.
4. Yellow colour indicates mix is pasteurized while lemon yellow colour
appears the acid phosphatase is active.
Percent Fruit:
1. Take weigh of ice cream.
2. Dissolve in water and separate the fruits using sieve.
3. Dry the fruit in filler paper.
4. Weigh the fruit.
% Fruit = (wt of fruit/wt of ice cream) x 100.
Specific gravity:
Apparatus: Picnometer, weighing balance.
Procedure:
1. Wash the picnometer with water. Clean it with tissue paper.
2. Keep the picnometer in hot air oven (101+-10C) for 10minutes.

3. Taken out the picnometer from oven and put in desiccators at normal
temperature.
4. Weigh the picnometer and note the reading (W1).
5. Put into distilled water up to the head.
6. Stopper it with knob.
7. Weigh the picnometer (W2).
8. Drain the distilled water.
9. Put the sample in picnometer.
10. Stopper it with knob.
11. Weigh the picnomenter(W3)
12. Calculate the specific gravity by the formula.
Sp. Gravity = (W3 – W1)/ (W2 – W1)
Moisture of Sugar
Object: To determine moisture% in sugar.
Apparatus: Metal dish, weighing balance.
Procedure:
1. Heat the two metal dishes in hot air oven at 101+-1OC) for 1 hour.
2. Put into dessicator at the normal temperature.
3. Weigh the dish on the weighing balance and note the reading (W1)
4. Put the 2gm of sugar and note the reading (W2).
5. Exactly the same procedure is done for another dishes to find out the No
variation.
6. Keep in hot air oven for 1½ hours at 101+-1OC).
7. Cool in a desicator for at least 10 minutes.
8. Weigh the both dish (W3)
%TS = (W3- W1) / (W2 – W1) X 100
Moisture = 100 – TS%
Brisk
Object: To determine the brix of candy mix.
Apparatus: Refratometer, pipette.
Procedure:
1. Clean the prism where a drop of mix is
to droped by tissue paper.
2. keep the drop of mix with the help of
pipette.
3. Close the shutter.
4. Adjust the light with the help of screw.
5. Find out the brisk of candy mix.
6. Sugar% <12%.
7. RI = 1.879
8. Sugar = 28%
Free Fatty Acid (FFA)
Object: To determine the FFA of cocoa butter.
Apparatus: Beaker, pipette, hot plate, weighing machine.
Reagent: N/10 NaOH, Phenopthalein spirit.
Procedure:
1. Take 10gm of cocoa butter.

2. Melt the sample.
3. Weigh 50ml spirit.
4. Neutralize with adding 1ml
Phenopthalein.
5. Titrate against N/10 NaOH till
pink colour appears.
6. Mixing with melted cocoa butter.
7. This mixture is boiled to its
boiling point with the help of hot plate.
8. Then it is titrated against N/10
NaOH till the pink colour appears.
9. Calculate the FFA% by formula:
FFA% = 2.82x Vol. Reading / Sample weight.
=2.82 x 3.15/ (10.1- sample weight).
FFA = 0.879%.
REFRIGERATION
Capactity: 250TR
Refrigeration is the process to bring the temperature of the system lower w.r.t the temperature
of the surrounding.
Unit of Refrigeration: TR (Ton of Refrigeration).
One TR is the amount of heat which is being required to withdraw from 1000kg of water at
0oC to convert it into ice of 1000kg at 0OC within 24 hours.
Latent heat of vapourization = 540Kcal/kg.

Latent heat of ice = 80Kcal/kg.
ITR = 3000 Kcal/Hr = 3.5 KJ/Sec.

Refrigeration plant capacity: 250TR
Evaporator = 250TR (Load)
Compressor
Grasso:
High stage compressor I: 203TR.
High stage compressor II: 203TR
Booster Compressor I: 60TR.
Booster Compressor II: 60TR.
Stall:
High stage compressor = 80TR.
Booster Compressor I = 25TR.
Booster Compressor II = 35TR.
Total Capacity: 200x2 + 60x2 + 80 + 35 + 25 = 660TR.
If the refrigeration cycle is running properly:

Evaporator load = Condenser load.
Condensor capacity:
270 TR / 250TR
300TR / 250TR
CONDENSER
COMPRESSER
RECEIVER
EXPANSION
EVAPORATOR VALVE
COP ( Coefficient of Performance)
COP = Evaporator Load / Compressor W.D
= (EE – ED) / ( EA - EE)
for good running condition, COP > 4
Compressor
Capacity I & II is 203TR
In Mother Dairy (ICP), the two stage compressor are used. This is because
1. Energy Saving.
2. Deep Chilling
In Walzer and extrusion line we have to maintain temperature -35 to -450C.

Type: 4 Single stage & Economized
Swept volume: 470 to 860 m3/h (270 to 507) (FM) at 2940/min (RPM).
Minimum discharge pressure: 25bar (363 PSI)
Parts of Compressor:
1. Suction Filter
2. Coupling Guard.
3. Oil Filter – 1
4. Oil Filter – 2
5. Oil Pump
6. Oil Separator
7. oil Cooler – Shell & tube type.
8. Discharge line.
CAP = Caps allied pressure ( 6bar)

SP = Suction Pressure (2.8 bar)
PV = Pressure Volume (2.85)
Grasso Machine Screw Series

Type: Screw type Compressor
Oil lubrication: G68
Oil Separator: 4 Filter.
Motor (Compressor)
Schorch
Made in Germany
Type: KA 7315L – A30 18-203 IEC 315L.
IMB 3
1998 Nr: 9170478/1
Frequency: 50Hz
Power: 200KW
Volt: 450V
Amp: 325A / 189A
RPM: 2975/min.
Nach: 2400h/26g Felt.
Din: 51825 – K3K
Seife / mineral Oil
Frequency: 60Hz.
Power: 230KW
Volt: 460V
Amp: 325A
RPM: 3575/min.
EN: 60034-1 IEC34-1
Oil Filter No.1

BBA Berliner Behalter – u Anlagenball GmbH
Herstell Nr – 1180
Herstelljahr – 1998
Oil Filter No. 2

GEA Grasso GmbH
Refrigeration Technology
Holzhauser str. 165
D. 13509
Berlin
Type: NB 5AG
Serien-Nr/Serial/No. 7120
Max,. Working Pressure: 23
Refrigerant: Ammonia.
Oil Separator
12439 Berlin Bruno – Burgel
Weg 122-140
High Stage Compressor No. 2

GEA Grasso
Grasso products BV S hertogenbose.
The Netherlands.
Oil Separator:
Type: ON 508 MB – NB
Manufacturing No.
98-1-045
Year 1998
Oil Filter No.1

Medium: OEL, Ammonia, R22.
Moto (Compressor)
Schorch
Type: KA 7315L – ABO 18-203 IEC 315L
IMB3
1998 Nr: 9170478/1
Frequency: 50Hz.
Power: 200KW.
Volt: 400V.
Amp: 325A
RPM: 2975/min.
Nach: 2400h/26g Fett
Principle of Compressor
The Principle of compressor is to take the vapour at low pressure and low temperature and
compressed it to high pressure and high temperature.
The compressor is the heart of the refrigeration system. A compressor is equipped with
sucion, discharge starting bypass, suction bypass and surge valves. Three general types of
compressor are used in dairy – reciprocating, rotary and centrifugal. Reciprocating
compressor are the most commonly used ones. Usually two or multiple cylinder vertical
single-acting compressor are used. Two – cylinder compressors have speed from 360 to 425
rpm and are used for ammonia. Multi-cylinder compressor are used for Freon-12 and Freon-
22 also, and have speed between 600 to 1800 rpm. Horizontal double acting compressor may
be used in a very large dairy plant.
Rotary compressor are suitable for low pressure range and small tonage capacity. Any of the
common refrigerant can be used in these units.
Centrifugal compressor are adaptable to a wide range of temperature from -20OC to 10OC and
are flexible under varying loads. Their speeds normally vary from 4000 to 6000 rpm. They
operates best with refrigerants possessing a high specific volume and therefore are used for
Freon-12 or Freon-22.
Screw Compressors:
The screw compressor is a more recent invention. The principle components are two helical
rotors which ate installed in a common housing. As the rotor turn, the gas is drawn into the
gaps between the teeth and is trapped in the clearances. As rotation takes place, the volume
between the teeth is continuously reduced as the capative gas is conveyed along the teeth of
the rotors. The gas is gradually compressed and the pressure increases. The compressed
vapour continues to condensers. Oil is sprayed on the meshing faces in most screw
compressors in order to reduce the leakage between the gaps in the rotors. In this way it is
possible t obtain high efficiency also at low speeds. The oil is removed from the vapour in an
oil trap before the condenser.
Screw compressor are used in large installations where the refrigeration capacity exceeds
500KW. One of the greatest advantage of the screw compressor is that the capacity can be
varied down to 10% of the full power without excessive losses of electric energy.
High Stage Compressor:

Suction pressure: 2 to 3 bar
Discharge Pressure: 9 to 14bar
Suction Temperature: - 10oC.
Discharge Temp: 60 to 75OC.
Oil Pressure: Below 17bar.
Oil Temperature: 30 to 60OC.
Oil difference pressure: More than 2 bar.
Cooling water pressure in oil temperature: around 2 bar.
Motor temperature: below 50OC.
Oil level in oil separator: Normal (2 Glass).
Booster Compressor No.1
Parts:
1. Suction Filter
2. Coupling Guard.
3. Oil Filter-1
4. Oil Filter-2
5. Oil Pump
6. Oil Separator
7. Oil Cooler
8. Discharge Line.
Oil Flow Diagram
Oil Separator
Oil Cooler (Shell & tube type. Water in shell and oil in tube.)
Oil filter
Oil Pump
Bearing Lubrication & Screw.
Oil Separator:
GEA
Grasso Products BVS Hertogenbosch
The Netherlands
Type: DN 508 MB-NB
Manufacturing No. Febr 98/1/046
Year: 1998
Weight (Empty): 325kg.
Schorch (Motor)
Type: KA7250M – ABO IB-Z.
IEC 250M, IMB3
1998 Nr. 56030802/2
Power: 55Kw
Frequencey: 50Hz.
Amp: 94Amp./55 Amp.
RPM 2960
Frequency: 60Hz
Power: 63KW
Volt: 460V
Amp: 94
RPM: 3560/min.
Oil Filter No.1

Motor (Compressor)
Schorch
Type: KA 7315L – ABO 18-203 IEC 315L
IMB3
1998 Nr: 9170478/1
Frequency: 50Hz.
Power: 200KW.
Volt: 400V.
Amp: 325A
RPM: 2975/min.
Oil Pump
Jahnradpumpenfabrik
Mannheium GMBH
Type: LG2/65F
RPM: 1403
Pressure: 6/23bar.

GEA
Grasso Products BVS Hertogenbosch
The Netherlands
Type: DN 508 MB-NB
Manufacturing No. Febr 98/1/046
Year: 1998
Weight (Empty): 325kg.
Oil Filter No.1

Moto (Compressor)
Schorch
Type: KA 7315L – ABO 18-203 IEC 315L
IMB3
1998 Nr: 9170478/1
Frequency: 50Hz.
Power: 200KW.
Volt: 400V.
Amp: 325A
RPM: 2975/min.
Oil Pump
Jahnradpumpenfabrik
Mannheium GMBH
Type: LG2/65F
RPM: 1403
Pressure: 6/23bar.
STALL
High Stage Compressor – 1
M/C No. 2703
Switzer (Style GM)
Model: 6M – 301 – 02 -658 – E.
Range: 0 – 1 – 1 5 bar.
Tag No. – SLENGTH= 5177 k1
Switzer instrument Ltd.
Madras
Type: RVA-59
S.No.: 91R59912
Manufactured in India in Callaboration with Stal. Refrigeration Swederr.
Oil Separator:
Oil Filter used in oil separator
Item Code: 160122
Part No.: 1898-516-2
Des 1: Filter Sil – 6 For oil Separator RVA Screw.
Des 2: Compressor, stal mint Mark-II, Type R59 K
Des 3: Article No 1898-516-2
Des 4:
Des 5:
Des 6:
Des 7:
Make – York Refrigeration
Lubrication of oil in HSC
Oil Separator
Oil Cooler
Oil Filter
Compressor
Stall Booster Compressor No.1

Machine No. 2701
Oil Separator:
Oil Separator 500 Dia
Design Code: Good Engg Practice
Code No. S81.36
S.No./year: 91/381 – 021991

Machine No. 2702
Oil Separator:
Oil Separator 500 Dia
Design Code: Good Engg Practice
Code No. S81.36
S.No./year: 92 – 413/1992
Design (OC): 10/125
Condensor
The condenser removes the heat from refrigerant carried from evaporator and added by
compressor and convert the vapour refrigerant into liquid refrigerant. The condenser and
other equipments in the system between the compressor discharge and expansion valve are
often referred to as high pressure side equipment. There are three general types of
refrigeration condensers.
Air-cooled, water cooled and a combination of air and water cooled usually refered to as an
evaporative condenser. The size of a particular type of condenser chosen for a given load
depends upon:
1. The heat transfer characteristics of the surface of the refrigerant and of the cooling
medium.
2. The temperature of the refrigerant and of the cooling medium.
3. The physical properties of the refrigerant allowances are also made for dirt and scale
collection on the surface.
 AIR COOLED CONDENSERS
 WATER COOLED CONDENSERS

i. Water cooled condensers.
ii. Double-tube condensers.
iii. Shell and tube condensers.
 EVAPORATIVE CONDENSERS
Shell and Tube Condensers:

They are large modern installation and with the smaller compressors when fouling of the
water is possible. The shell and tube condenser consist of a shell with a tube sheet securely
fastened to each end. Each tube sheet has an easy removal header type cover, which is often
baffled to cause the water to flow back and forth through the shell several times. This baffling
increases the water velocity for a given flow and in turn the heat-transfer coefficient. These
condensers are available from 2 to 1000 tones capacity.
Condenser Capacity: 270TR.
Pump (Centrifugal Pump):

Through the pump the warm water goes to the cooling tower.
1. Pump No. 1 10HP

2. Pump No. 2 10HP
3. Pump No. 3 10HP
4. Pump No. 4 30HP
5. Pump No. 5 30HP
6. Pump No. 6 7.5HP
7. Pump No. 7 7.5HP
8. Pump No. 8 7.5HP
Cooling Tower:
Cooling towers are used in water cooled heat exchanger or a shell and tube condenser. In
cooling towers the warm water is sprayed in air stream. Some of the water evaporates. The
heat required for the evaporation comes from the remaining water which is cooled. The more
the water evaporates the cooler will be the remaining water. To increase the efficiency of a
tower, the contact between the air and the water must be the best possible. This indicates that
there must be sufficient quantity of air and the water must be broadly dispersed. An efficient
tower will cool air to within 3.5 to 5OC of the air wet bulb temperature. 4OC being considered
the most economical.
The most common towers utilize forced or induced draft produced by fans, which blows or
draw large quantities of air through the tower structure. Instead being sprayed water passes
over a large no. of surfaces called the packing of the tower. In the past, the packing was made
of a large quantity of redwood or cypress state laid closed together. However, molded plastics
forms are becoming more common now.
When the water required for condenser is inadequate and expensive then the same water is re-
cooled and used again and again. The cooling towers are is used for larger installations,
absorption refrigeration units and centrifugal refrigeration units.
The cooling tower may be classified as atmospheric or natural drafts of the spray type. The
water from the condenser is sprayed through the nozzles. To expose the maximum of water
to the air to allow the droplets surface to evaporate and cool the water.
The major disadvantage of this is that, it requires more floor area per kg of water than any
other system used cooling.
The size of the equipment required is affected by:
1. The cooling temperature range of the water.

2. The difference between entering air wet bulb temperature and leaving water
temperature and,
3. Time of contact of air and water.
In Mother Dairy’s ice Cream Plant, there are 5 cooling tower

 2 are of 80,000LPH
 3 are of 1,20,000 LPH
Cycle of Concentration:
The circulating water becomes concentrated with respect to the solid content due to the
evaporation loss of the circulating water. The COC is the term of employed to indicate the
degree of concentration of the circulating water compared to the feed water and is measured
in relation to any one parameter (TDS, Total Hardness or Cl content).
Scale Formation:
Dissolve mineral matter mainly consisting of carbonates and bicarbonates reach a stage due
to concentration when they precipitate from solution as scale.
Corrosion:
Corrosion is promoted by a number of factors:
1. Dissolve gases (O2, CO2, H2S)

2. Dissolved Solids
3. Micro organisms
4. Electrochemical effects
5. Water flow rate.
Corrosion Inhibitors:
A corrosion inhibitors decrease the corrosion rate and is effective when added in small
concentration to the circulating water. They are composed of chromate. Phosphate and zinc
salt in combination. These inhibitors act by forming a protective film on the metal surface
thus prevent the surface from electrochemical phenomena of corrosion.
Microbial Fouling:
Various types of organism are continuously introduced into the water through wind blown
dust. These can cause the algae deposition and corrosion thus lowering the cooling efficiency.
Control:
1. Control of scale formation
2. Control of corrosion
3. Control of fouling
Control of Scale formation:

Scale can be defined as solids in solution which are deposited on heating surface. Major scale
forming constitute laid down by re-circulating water consists of CaCO3 Calcium sulphate
calcium phosphate. The solubility of calcium phosphate depends on pH temperature and
calcium concentration. Thus lowering of pH with H2SO4 helps to prevent scale formation in
most cases. Polyphosphates along with organics have also been used for scale prevention.
Control of Corrosion:
The different corrosion control measures can be divided into three categories viz. corrosion
control by the use of inhibitors and corrosion control by cathodic protection. Corrosion
protection by use of inhibition has been widely used. Zinc has also been used in many
inhibitory properties.
Control of fouling:
Fouling is opposed to scaling is the deposition of solids normally in suspension in the
circulating water.
Fouling can be of two types:
1. Natural.
2. Artificial.
Natural:
Natural fouling involves material that exist in the system as a result of factors external to the
system. This can be salt clay, mud, natural organics, sand, iron etc.
Artificial Fouling:
Artificial fouling is caused more by system characteristics such as corrosion product, clarifier
carryover, aluminum & iron phosphates, microbial growth and products contamination.
The method of control:
1. Reduction of suspended solids by clarifying the make up water.

2. Locating the tower far from dust and contaminants.
3. Side stream filtrations and use of dispersants.
Microbial Fouling:
They can be generally classified as:
Oxidizing
Non oxidizing biocides
Bio-dispersants
Oxidizing biocides literally ‘burn-up’ any microbe, they came in direct contact, chlorine is a
very commonly used biocide because it is inexpensive. Chlorine should be introduced
directly in the basis and carefully monitor in the return water and chlorine level in return
water should not be allowed ti exceed 1PPM otherwise can lead to severe damage to tower
wood.
Use of Non oxidizing biocides available but they can not be directly disposed off in blow
down.
Some of the non-oxidising biocides are:

1. Sodium pentachlorophenate. (NaPLP)
2. Quaternary ammonium compounds.
3. Methylene b is –thiocynate
4. Dichloro Diphenyl Methane.
Cooling of water from cooling tower depends upon:

• Area water.
• Air
• Evaporation
Liquid Receiver:
The receiver is a vertical or horizontal storage tank in which the liquid refrigerant is held
under pressure ready to be used in the evaporator. The receiver is equipped with a valve
connection to change the system with the proper amount of refrigerant.
Specification:
Make: Indian Dairy Machinery Co. Ltd.
Client: Mother Dairy Delhi.
Manufacturing Serial No.: 2129-2
Purchase order No. and date: NL 601 12-01-98
Design Code: 152825-1969
Class 1A
Working Capacity: 2140Ltr.
Empty Weight: 940kg.
Working Temperature: 70oC.
Hydrotest pressure: 27kg/cm2.
Operating fluid: NH3.
Air Purger
Air purger is fitted on top of the receiver. In the receiver the liquid ammonia is in the bottom
and remaining vapour ammonia is at the top. The function of air purger is to take the air from
liquid ammonia. It prevents te air to go in the system. Air Purger works on the principle of
refrigeration cycle.
Oil Rectifier:
It is a shell and tube type. Hot gases (vapour ammonia) is in the tube and liquid ammonia and
oil is in the shell. Due to contact in hot gases liquid ammonia vapourized and goes to the LG
Cooler. Due to gravity oil come at the bottom which is drained out. Sometimes oil come from
the compressor and goes to receiver and then oil rectifier. Oil and vapour come together from
the compressor.
Specification:
Make India Dairy machinery Co. Ltd.
Vithal Udyognagar – 388121 Gujarat
India.
Client Mother Dairy Delhi.
Working Capacity: 0-65m3.
Economizer:
The function of economizer is to minimize the cooling load. It is shell and tube type. Liquid
ammonia is in horizontal tube at 35OC and pressure 11bar. Liquid ammonia and vapour are in
shell. Its temperature and pressure are -10OC and 2.8 bar. Before the liquid ammonia enters
the tube in economizer there is thermo static expansion valve which reduce the pressure and
expand the liquid. Cooling occurs between liquid to liquid ammonia. The vapour ammonia
which remains in the receiver then comes to economizer is discharged to high stage
compressor at 11bar. And 35OC and discharge at 20OC. It is fitted with between LG cooler
and receiver.
Specification:
Client: Mother Dairy Delhi.
Manufacturing Serial No.: 2129
LG Cooler:
The function of LG cooler is to reduce the pressure and temperature of liquid NH3. This is
the shell and tube type. Liquid NH3 is in the tube and in the shell. The cooling is in between
liquid to liquid NH3. Here pressure raise to 11bar to 12bar and temperature drops to 35OC to
10-15OC. The liquid ammonia HN3 in the shell has a temperature of -10 OC and pressure
2.8bar.
Specification
Client: NDDB, Delhi.
Manufacturing Serial No.: 2129
Design Code: 1S-2825-Class 1A
Working Temperature: 60OC. (max.)
Design Temperature: 100OC.
Design Pressure: 18kg/cm2.
Accumulator:
Liquid NH3 having a pressure of 12bar and temperature 10-15OC passes through the
accumulator. In the accumulator the liquid ammonia passes through the deep freezer 1, 2,
Extrusion line, walzer-2. In the DF1 and DF2 heat is exchanged. Liquid NH3 takes the heat
from the storage and converted into vapour ammonia. This vapour ammonia passes through
the accumulator. Here again cooling is in between vapour NH3 and liquid NH3. Here liquid
NH3 passes through the DF1, DF2, Ext, W1, W2 and vapour goes to the low stage
compressor (booster compressor). The vapour NH3 having a pressure of 0.7bar &
temperature -40OC goes to the LSC and compressed it into 2.8 to 3 bar and temperature 70-
75OC. The discharge of the booster compressor passes through the LG cooler. Vapour
ammonia mix in the LG cooler and drops the temperature to -10OC and pressure becomes
2.8bar. From LG cooler vapour ammonia having a 2.8bar & -10OC passes through the HSC.
Expansion Valve:
It is the device which controls the rate of flow of the liquid refrigerant between high pressure
and low pressure sides of the system.
Changes which takes place before and after expansion:
BEFORE AFTER
Temperature More Low

Pressure High Low
State Liquid Liquid
Mass Same Same
Evaporator:
AN evaporator is that part of a refrigerating system in which refrigerant is vapourized to
produce refrigeration. The refrigerant come to evaporator below the temperature that is
required to maintained in evaporator/product. The evaporator is also known as cooler or
freezer.
Capacity of Overall Refrigeration Plant:
STALL:
Booster Compressor 1: 90284Kcal/h = 35TR.
2: 61910Kcal/h = 25TR.
High Stage Compressor: 214981Kcal/h = 80TR.

Total Capacity of Refrigerant (Ammonia) Plant:
203+(60x2)+80+35+25
= 460TR.
GRASSO:
Hig Stage Compressor I & II: 203TR
Booster Comprssor I & II: 60TR.
New Plant
DF3 & DF4: 50182KCaLength= 15x2
Candy: 60000 KCal = 20
Extrusion:100000 KCal = 35
Cold Store: 20000 KCal = 70
Old Plant
Dry Fruit: 6191 Kcal = 2TR
IBT: 45572 Kcal = 15TR
DF1 & DF2: 41273 Kcal = 13TR x 2
Frozen Fruit: 6191 Kcal = 2TR
Eutectic tank: 19777 Kcal = 7TR
Hardening Tunnel: 100000 Kcal = 35TR.
BOILER
Boiler is a closed vessel exceeding 22.75 liters (5 gallon) in capacity, which
is used for generating steam under pressure and includes any mounting or other
fittings attached to such, which is wholly or partially under pressure, when steam is
shut off. There are two types of boilers viz. Fire tube and water tube type boiler. At
Mother Dairy, Two Fire Tube Boilers are installed.
The fuel used here is L.D.O (Liquid Diesel Oil). The fuel is allowed to mix
with air in ration 1:15 ( one part of L.D.O to 15 parts of O 2). The fire generated from
the L.D.O inside the tube is allowed to move in spiral movement. The tube is having
3 turns inside the vessel to get maximum efficiency.. This tube is surrounded with
the water to be heated and converted to the steam. The heating of water is through
the heating surface of the tube by conduction. The heating effect obtained from the
L.D.O fuel is between 180OC to 220OC. For complete combustion of fuel mixture the
tube should contain approximately 20% oxygen, which is injected with the help of
blower. Completeness of combustion can be detected by analyzing the gases released
from the chimney. 3 – 4% O2 concentration or 12 – 13% CO2 concentration indicates
complete combustion of fuel. Another method of detecting the completeness of
combustion is by analyzing the color of the gaseous mixture then is released from the
chimney. The ideal color should be light brown Grey. The temperature of released
gases at 180OC and above. The steam so produced has temperature more then 150OC.
Causes of Incomplete Combustion :-
• Less air
• Improper mixing of fuel and air, poor atomization.
• Nozzle Worn or Plugged.
• Oil Temperature too low.
• Heat loss for every kilogram of un-burnt carbon is 8084
Kcal.
Checking of Improper Combustion :-
• Flame length should be 2/3 to ¾ of furnace length.

• Smoke should be light brown.
• Carbondioxide in fuel gases should be 12%.
• Oxygen should 4 to 4.5%.
• Color of flame should be golden orange or dark yellow.
•Stack Temperature in oil fired boiler should be 180 to 220OC.
Energy Conservation :-
• Leakage in oil line: Leakage @ 1 drop/second result in

4000 Liter per year loss of oil approximately Rs: 70 per day.
• Leakage of steam through 3mm hole at 7kg/cm2
pressure is 32000 liters oil of a year is approximately Rs: 550
per day.
• 1 mm soot boiler tubes means 5% loss of fuel oil.
•200C increase in stack temperature is equal to 1% fuel loss.
•60C increase in water temperature is 1% saving of fuel oil.
• Condensate return used 100% is 10% saving of fuel.
EFFICIENT OPERATION OF BOILER :-
• Gap of electrodes 5 to 6 mm, Voltage should be 14500 V.

• Chimney smoke should be light brown Grey.
• Flame should not feeding, it should be steady.
• No oil is dripping near burner or in oil lines.
• Flame length should be adjusted according to the length of
furnace.
• All the safety control devices are in proper working condition.
• Any abnormal sound in boiler pump, motor should be
observed.
Technical Specifications are given below :-

CAPACITY PER HR 4 TON
WORKING PRESSURE 10.5 KG/SQ.CM
HEATING SURFACE 100 MTR.SQR.
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 process it to produce Toned Milk, after doing the
pasteurization. The standards for the processed Toned Milk are as follows:
Fat contents: 3.05%

Solid non-Fat contents: 8.58%
Temperature: 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
RAW MILK RECEPTION :- This is the first stage of the milk processing. In this
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 Number of unit installed

Pasteurizer 05
Homogenizer 04
Clarifier 06
Silos 14
Ice Silos 02
Raw milk Silos 05
Processed milk silo 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 10°C
4. ORGANOLEPTIC EVALUATION
Check., taste and flavour 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 titratable acidity.
7. ROSALIC ACID TEST

To 2 ml rosalic acid in a test tube add 2 ml of milk . Rose red colour 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 gerbers 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
Milcoscan is the latest technology machine for scanning of milk and uses infra red
rays to analyze the milk for
• Fat
• Protein
• Lactose
• SNF
10. 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 37°C in a water bath. Check
the tube for decolourization 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 colour 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 colour 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 colour 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 colour. To this add exactly 1 ml of
milk and mix. Observe the colour if yellow colour 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 40°C. 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. Take 1 ml of milk in each of the two sterilized MBR
test tube.
3. Heat One Tube to boil to act as control sample.
4. Add 5 ml of Phosphatase dye in each Tube and mix
well.
Incubate at 37 dig.C in water bath, observe the color after 10 minutes, 30
minutes and finally after two hours. Yellow color indicate 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
oxidation-reduction 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

Keep milk samples of first and final testing in sterilized 125 ml glass bottle in
incubator at 37°C.Note the time. Check for COB after 3 hrs first and then every
hour till it becomes COB positive. Note down the % TA. Note total hours taken
for milk to become COB positive. Observe for any abnormality such as cream
layer, fat or powder separation
TITRABLE ACIDITY
Take 10 ml milk sample to it add 10 ml distilled water add Phenopthalein 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 colour 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 7°C 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 leave Mother Dairy.
(2) 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 40-45°C because of outgoing
milk and hence reducing its temperature. Regeneration system helps in energy saving
both for heating as well as cooling milk
(3) Clarification: Clarification is the process of removing suspended foreign by

centrifugal sedimentation – clarifies are used for this purpose.
(4) 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.
(5) Homogenization :- Homogenization is a process wherein fat globules are broken

down to 2 microns or less under high pressure Homogenizer is a machine which cause
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 cavitation 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 APV GAULIN
Capacity 18000 LPH
I Stage Pressure 1800-2400psi (140 bar)
II Stage Pressure 500-700psi (14bar)
Motor 125 HP
(6) Pasteurization:. Here milk is heated using plate-heat chiller to a temperature of 76-
78°C and the temperature should not be less than 75°C so as to ensure proper
pasteurization and not greater than 79°C 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 75°C the forward milk flow is maintained. But
by continuous monitoring it is ensured that the temperature is maintained at 76-77°C. At
the same time it is also seen that the temperature do not exceed 79°C 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.
(7) Chilling: Here milk is finally chilled to 4-5°C using chilled water which are
being pumped from ice silos. The chilled water temperature ranges from 1.5 - 3°C and
chilled milk temperature from 4 - 6°C. If the chilled milk temperature exceeds 9°C 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 rises continuously the refrigeration section take necessary action
in this regard so as to reduce the temperature. After chilling, milk is pumped to the silo’s.
(8) 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 litres of milk so that the milk
contain 2000 IU of vitamin A.
(9) 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 samples are 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.
DESPATCH
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 2°C in glycol chillers. Here instead of chilled water, chilled glycol of
approximately –0.5°C is passed into the chillers. The chilled milk is then filled in tankers
and the tankers then go to the milk vending shops for sales.
CLEANING IN PLACE (CIP) SYSTEM
Containers and machines working on milk are subject to the gradual growth of
bacteria with the passage of time. So in order to ensure the proper processing of milk is
done and no bacteria passes to the processed milk the milk containers i.e. the silos and the
plants have to be cleaned after eight hours of use with milk. So in order to ensure proper
cleaning a proper CIP plant is required. This plant is used to clan the silos and the plants in
their own place. Further the CIP process is dependent on the type of the machine/container
and there are only slight variations to the general procedure.
The cleaning process in general contains the following steps:
FLUSH WITH FLUSH TO DRAIN

FRESH WATER TO WITH RECUP LYE RINSE
RECOVERY WATER
FLUSHING WITH ACID RINSE FLUSHING WITH

HOT WATER HOT WATER
FLUSH WITH
STERILISATION
FRESH WATER TO
WITH HOT WATER
RECUP TANK
PROCESSING PARAMETERS
 PASTEURIZER
 Milk flow in the plant 16000-18000 LPH

 Pasteurization temperature 76-780C
 Chilled water temperature 1-20C
 Chilled milk temperature 4-70C
 Milk pressure in the plant 2-3Kg/cm2
 Regeneration Efficiency More than 90%
 Milk/water leakages No leakage
 CLARIFIER
 Oil level 1/2 of level view glass

 Speed 6250 RPM
 Milk pressure in clarifier 4 bar
 Make up water pressure 1.5 kg/cm2
 Flush water pressure 1.5 - 2kg/cm2
 Motor current 30-34 amps
 Discharge interval 20 minutes
 Discharge qty 10 Liters (approx.)
 Abnormal sound No
 Abnormal heating No
 Abnormal vibration No
 Leakages No
 HOMOGANIZER
 Lubrication oil level 1/2 of level view glass

 Lubrication oil pressure 1bar(Minimum)
 Milk pressure in HVA 2000 PSI
 Cooling water for piston spray should be visible
 Cooling water for oil Visible in the drain point
 Tension of belt Normal
 Oil leakage No oil leakage
 Milk leakage No oil leakage
 Water leakage No oil leakage
 MILK PUMPS
 Shaft seal leakage no leakage

 Milk flow in the pump 16000-18000ltrs/hr
 Proper fixing of pump cover Yes
REFRIGERATION PLANT
 SCREW COMPRESSOR
 Suction Pressure 3 bar

 Suction temperature 40C
 Discharge Pressure 12 bar
 Discharge Temperature 80 deg c
 Oil pressure 7-8 bar
 Oil temperature below 600C
 Oil differential pressure below 1kg/cm2
 Cooling water temp-in 300C
 Cooling water temp-out 340C
 Cooling water pressure 2 bar
 Motor current 500 amps
 Oil/Gas/water leakage No
 COOLING TOWER
 Oil level in gear box Normal in level marker

 Water flow thru distributor Even distribution
 Inlet/Out let water temperature 40C delta t
 Water quality (hardness) 150 ppm
 Pump gland leakage No
 Oil/water leakage No
 CONDENSER/RECEIVER

 Inlet/Out let water pressure below 1 bar deferential
 Liquid level in receiver minimum 1/3 level gauge
 PUMP SEPARATOR
 Liquid level Normal

 Functioning of solenoid making on/off as per level
 Liquid temperature 20C
 Seal leakage No
 PLATE HEAT EXCHANGER (PHE)

 Inlet/Out let water pressure 3-2 kg cm2
 ICE SILOS/PUMPS
 Water level Full

 Ice thickness 35 mm
 SOFTNER
 Water quality Below 100ppm hardness

 Water Flow 30000 LPH in each softner
 Water pressure 2.5-3.5 Kg /Cm2
 Brine Qty tank full
 Operation of pumps 2 pumps at a time
 Pump current around 14 amps
 Raw water level in reservoir Above minimum level
 AIR COMPRESSOR
 Lubricating oil pressure 1.5-2 Kg/cm2

 Lubricating oil level Normal level
 Cooling water Continues flow
 Loading unloading system Loading at 6.0Kg/cm2
 Un loading at 7Kg/cm2
 Suction filter Dust free
 Air leakage No leakage
 Water leakage No leakage
 COMPRESSOR MOTOR
 No load current 15-17Amps

 Load current 33-35Amps
 Belt tightness Normal
 Vibration level Normal
 DE HUMIDIFIER
 Temperature 3-60C
 Pressure 6-7 KG/CM2
 Air Pressure 6-7 KG/CM2
 Functioning of timer ½ hr interval
for condensation drain
 BOILER
 LDO in tank Normal level in service tank
 Water level in boiler Normal level
 Inlet oil pressure 20 KG/CM2
 Return oil pressure 6KG/CM2
 Feed water pressure 7-8 KG/CM2
 Functioning of air modulator Normal
 Functioning of solenoid valve Normal
 Functioning of ignition electrode Gap between electrode 3-5mm
 Stack temperature 180-2000C
 CO2/O2 level 12±5%/ 3-4%"
 Functioning of PRV 3-4 KG/CM2
 Functioning of safety valve 9-10 KG/CM2
 TDS of water below 5000ppm
 Hardness of water Below 10ppm
 Blowdown of feed water Twice in a day for 1minute
 ROTARY BLOWER
 Lubrication Oil level Half of the view glass

 Suction filter Dust free
 coupling Fully tight
 Foundation Bolt fully tight
 Alignment Proper
 Air pressure 3 bar
 Air leakage No leakage
 DEHUMIDIFIER
 Chilled water inlet pressure 3 kg

 Chilled water outlet pressure 2 kg
 Chilled water inlet temperature 20C
 Chilled water outlet temperature 80C
 steam inlet pressure 3 bar
 steam outlet pressure 2 bar
 Outlet air temperature around 400C
 Relative humidity around 20
 TRIBLENDER
 General cleaning dust free

 abnormal sound smooth running
 vibration no vibration
 alignment proper
 Belt tightness proper
 Load current Below 20 amps
 Mixing rate 3ton/hr
 BUTTER MELTER
 General cleaning Dust free

 Foreign material No deposition
 Leakages No steam leakages
 Butter leakage No
 Filter No deposition of foreign material
 Level Sensor Pump operation as per level
 Function of drum Smooth function of drum
 Temperature of butter 60-650C
 Steam Steam pressure 3-4 Kg/cm2
 EFFLUENT TREATMENT PLANT
 Raw Effluent Pump On / Off operation of pump

Stopping on low level .
Staring on high level.
 Smooth running No vibration
 Normal operating current Below 20 amp
 NUETRALIZATION TANK
 Water level Normal level

 Agitation Proper air supply
 PH 5.5-9 ppm
 AERATION TANK
 Working of aerators No vibration

 Normal operating current around 30 amp
 Dissolved Oxygen 0.7-1.3
POWDER HANDLING SYSTEM
 ROOTS BLOWER
 Make Kay International

 Type Roots
 Conveying gas Air
 Motor RPM 1440
 DEHUMIDIFIER
 Make Virtex Engineering

 Type Heat Exchanger
 Gas Air
 DUMPING PIT
 Make IDMC
 MOC AISI 304
 BLOW THROUGH VALVE
 Product name Milk Powder

 Make DMN Westinghouse
 Type BL 300
 ROTARY VALVES
 Product name Milk Powder

 Make DMN Westinghouse
 Type AL 250
 BAG FILTER
 Make Reico
 Type Bag type
QA & RND LABORATORY

MILK POWDER
- On arrival of powder, draw sample from store godown

- Note down the source, batch number, date of manufacture and bag number from
which sample is drawn
- With the help of store staff keep six bags, possibly of different batches from each
truck, one bag after unloading 70 bags
- Open the bags carefully and take a composite sample of the truck from all the six bags
in polythene bags/bottles. Also take one bacteriological sample
Powder specification
SMP WMP
Fat% 1.5 (max.) 26.0 (min.)

Moisture 4.0 (max.) 4.0 (max)
Insolubility index 2.0 (max.) 2.0 (max)
Rosalic acid negative negative
Ash 8.2 (max.) 7.3. (max.)
T.A 1.5 (max.) 1.2 (max.)
TESTS
1) Moisture %
Using infrared moisture analyses.
Procedure
i) Switch on the instrument. Light will start blinking in start key.
ii) Press on/off/zero bar. Screen will display weight. Reset zero by pressing the
rezero bar, the balance is ready for worker.
iii) Set the temperature and time
SMP - 6 min. - 100 C

WMP - 6 min. - 100 C
To set the temperature, press the key showing thermometer and the temperature will
be displayed. The required temperature can be adjusted by pressing key up or down,
then enter for time press the key indicating watch and set the required time, then
enter.
iv) Open the top of the instrument and spray powder on the pan evenly distributed
till the balance achieves the 5 gms weight of powder and close the top.
v) Press 'start'. The balance will show zero. After completion of time start key
will start blinking and the balance will display the percentage of moisture.
2) Titrable Acidity
Material required: 100 ml beaker, 10 ml pipette, glass rod, and phenolphthalein

indicator, N/10 NaOH
Procedure
Weigh accurately 1 gm of the sample in a 100 ml beaker. Add 10 ml of hot distilled

water and make a solution using a glass rod. Cool to room temperature. Add 1 ml
phenolphthalein indicator and titrate against N/10 NaOH till a faint pink colour
persists.
Result: - The acidity present as volume of TA% = (NAOH used x 0.9)
3) Fat
Gerber's method
It is a common method of determining the fat content of milk
Reagents: - Sulphuric acid (1.0 - 1.812 specific gravity)

Amyl alcohol (0.85 specific gravity)
Procedure:
1.69 gm of milk powder is weighed accurately and dissolved in minimum amount of

home-distilled water. It is then carefully added to the 10 ml concentrated sulphuric
acid in a milk powder butyrometer so as not to allow mixing of milk with acid. Add 2
ml amyl alcohol to it and close the butyrometer. Mix the contents until all curd has
been digested. Transfer the butyrometer in the water bath at 65 C for 3 min. Place
the tube in the centrifuge at 1100 rpm for 5 min. Transfer the butyrometer in the
water bath at 65 C for 5 min. Adjust the fat column with the scale of butyrometer and
note the reading.
4) Rosalic Acid test:
Take 2 ml rosalic acid (0.05% in 60:40 alcohol In distilled water) in a test tube. Add
2 ml reconstituted powder. Rose red colour indicates neutralizer presence in powder
and formation of flakes indicates alcohol test positive.
5) Scorched particles:
Observe the bottom of the flask in which powder is reconstituted after keeping
undisturbed for some time. Filter the reconstituted milk through scorched particle
tester and compare the filter pad with ADMI comparison card. Powder with scorched
particles more than disc B reading is rejected.
6) Ash Content
Weigh 3 gm of powder in a well-dried silica crucible and heat on a heater till no

smoke comes out of powder. Keep it into a muffle furnace maintained at 550 + 20 C
for 3 hrs till grey ash formation. Switch off and transfer to a desicator. Cool and
weigh it. Heat the dish again at 550 + 2 C for 30 min. cool in descicator and weigh.
Repeat until difference between two successive weighing is less than one milligram.
Record the lowest mass.
Ash % by mass = 100 (M2 - M)

(M1 - M)
M2 = weight of crucible with ash
M = weight of empty crucible
M1 = weight of crucible with powder
Ash% on dry matter bases = Ash% by mass x 100

(100 - moisture%)
7) Bulk density
Materials required:- Bulk density meter, electronic weighing balance

Procedure:- Weigh 30 grams of powder in 100 ml cylinder. Fix the cylinder in the
frame of bulk density apparatus. Switch on the apparatus. The apparatus will take 30
strokes. Note the volume of the powder in the cylinder.
Density = Mass
Volume
8) Insolubility index
Materials required: - Centrifuge tube, centrifuge, and silicone antifoaming agent
Procedure:-Weigh 13 gm of WMP or 10 gm of SMP and reconstitute in 100 ml

distilled water at 24 + 0.2 C. Add 3 drops of silicon antifoaming agents and mix it
thoroughly in the blender for 90 sec. Further add 3 drops of silicone antifoaming
agent to the mixture and mix thoroughly with spoon for 10 sec. Pour the mixture into
a centrifuge tube up to 50 ml. Mark. Place the centrifuge tube in the centrifuge and
rotate it for 5 min. at 20-25 C. Hold the centrifuge tube in a vertical position and
remove supernatant liquid. Add water up to 30 ml mark in a centrifuge tube.
Completely dispense the sediment with the stirring rod and make up the volume up to
50 ml mark invert the centrifuge tube 5 times to mix contents thoroughly. Place the
tubes in centrifuge and rotate it for 5 minutes at 20-25 C. Remove the tube, hold in
vertical position and read the volume of the sediment to nearest 0.05 ml and it denotes
the insolubility index.
Adulteration detection tests
1) Rosalic acid
Take 2 ml rosalic acid (0.05% in 60:40 alcohol + distilled water) in a test tube. Add 2 ml
of reconstituted powder. Rose red colour indicates neutralizer presence in powder
2) Alcohol test
Take 2 ml of 68% alcohol in a test tube. To it add 2 ml of reconstituted powder.

Presence of flakes indicates alcohol positive and such powder is rejected.
3) Maltose dextrin test
Take 20 ml of reconstituted milk sample. Boil and coagulate the milk using 10% citric
acid solution filter through whatman's filter paper No.-42 and collect the filtrate. Add 3
drops of iodine solution to 5 ml filtrate and mix.
Chocolate brown colour indicates the presence of maltodextrins
4) Urea detection test
Take 2 ml milk in a test tube, add 2 ml DMAB solution and mix the contents.
Appearance of yellow colour indicates the presence of urea making the milk
unacceptable.
WHITE BUTTER
Specifications of white butter
Fat % = 82.0 (min)

Moisture % = 16 (Max)
Curd % = 1.5 max.
T.A. = 0.06% (Max.)
F.F.A. = .8 (max.)
B.R. = 40-45
Sampling
On getting information from stores about white butter arrival follow as under:
Check the temperature of white butter from three different places i.e. front, middle and
rear positions of the van.
Inform the temperature to assistant manager. With the help of store staff keep 6 cartons
possible of different batches, one carton after unloading 70 cartons from each van. Take
additional one carton for every additional 4 metric tons of white butter. Note down the
batch number, source and date of manufacture of all the cartons and also note the
condition of packaging/packed material.
After opening the carton check for any visible mould growth/abnormality. With the help
of butter trier/spatula take 2 or more plugs from different portions of white butter carton
and transfer to bottle/polythene bag. Similarly take white butter from other cartons
chosen and make one composite sample for one van. Also take one bacteriological
sample from each van.
TESTS
1) Fat, Moisture and Curd
Weigh a beaker previously dried in dessicator. Weigh 10 gm of butter (softened

not oiled) in beaker and heat on a hot plate till foaming ceases and curd attains
characteristic brown colour. Allow it to cool in the dessicator. Weigh it (Z gm) and
calculate the moisture.
Warm the beaker and add 50 ml of petroleum ether/petroleum spirit into it. Mix
well with a glass rod. Allow curd portion to settle down. Decant fat portion carefully
without disturbing curd portion.
Give 2 more washings with 30 ml petroleum ether. Clean the beaker with cotton soaked
in petroleum ether/petroleum spirit from outside.
Dry the beaker in hot air oven at 100 + 1 C for 30 minutes. Cool the beaker in a
desiccators to room temperature and weigh(w gm).
Calculate as follows:
Moisture % = Y - Z x 100
A
Curd = W-X
A
Fat = 100 - Moisture - Curd
X = weight of empty beaker
Y = weight of beaker with butter
Z = weight of beaker after removing moisture
W = weight of beaker with curd

A = weight of butter ( Y - X)
2) Titrateable acidity
Materials required: 250 ml conical flask, measuring cylinder

N/50 NaOH, phenolphthalein indicator
Procedure: Weigh accurately 20 gm of butter sample in 250 ml conical flask. Add 90 ml

of hot previously boiled water and shake the contents. While still hot titrate with N/50
NaOH using 1 ml phenolphthalein indicator
Calculation
Acidity% = 9 x V x N
W
Where
V = volume of NaOH used

N = normality of NaOH
W = weigh in grams of sample taken
3) Free Fatty Acids
Procedure: Melt the butter and prepare ghee out of it. Weigh accurately 10 gram of ghee
in 250 ml conical flask carefully. Add 50 ml of neutralized rectified spirit to it and heat to
boiling. Titrate against N/10 NaOH using phenolphthalein indicator.
Calculation
Free fatty acids = V X 2.82

W
V = Volume of NaOH
W = Weight of sample taken
4) Butyrorefractometer reading for butter ghee, butter oil etc:
Butro refractometer reading using digital refractometer. Clean the prism of digital
refractometer gently. Check the brix value of glass-distilled water at 40 C. It should be
zero. Dry the prism properly and put few drops of melted ghee and take reading in nDT
at 40 C. Instrument will show refractive index. Convert refractive index reading in BR
reading with the help of a chart. After completion of work clean prism with rectified
spirit, glass distilled water by using soft tissue paper. Switch off the instrument after use.
PRODUCTS
PANEER
Appearance: -Shall be clear and free from dirt, surface discolouration and insect's
contamination. It shall not have any free moisture.
Flavour: -It shall have pleasant odour and characteristic mild acid flavour
Texture; - It shall have a closely-knit smooth texture and spongy body.
Standards
Moisture Max. 60
Milk fat Min. 50 (db)
T.A. 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 - Gerbers Method
Reagents - Sulphuric acid (1.8 - 1.812 sg), Amyl Alcohol (0.85 as

specific gravity)
Procedure
- Take exactly 10 ml of gerbers 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.
Acidity
Reagents: N/10 NaOH and phenolphthalein indicator
Procedure
- 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 colour.
Calculation
Titrateable acidity % = (10 - Vol. Of HCl) x 0.9

2
DAHI/MISHTI DOI
Colour: - 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
Flavour
It shall have a pleasant and cream acid taste. It should be free from bitterness,
saltiness or other off flavours.
Standard
Fat % (Min). 4.6

TS% Dahi 15
Mishti Doi 31%
TA (Max). 1.2
Fat Determination
Reagents: - 25% Ammonia, Gerbers 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 Dahi in 40 ml beaker. To it add 20 ml distilled water and

acidity can be determined using acidometer.
LASSI
Colour: - White, uniform, without showing any sign of visible foreign matter.
Body & Texture: - Smooth and free from gas bubbles
Flavour: - Pleasant and sweetish aroma. It should be free from bitterness, saltiness or
other off flavours.
Specifications
Fat% min 3.1

TS% min 20
TA max. 0.8
Incubation Test
PH variation 0.3 max

TA - 0.02 max
Bulging Test - Negative
i) Fat determination
Gerbers Method
Carefully dispense 10 ml of Gerbers sulphuric acid in a butyrometer. Pipette out

10.75 ml of lassi 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 lassi in a 50 ml beaker. Add about 30 ml distilled water.
Determine the acidity under the curd mode in the acidometer.
FLAVOURED MILK
Appearance: -There should be no separation of fat or sedimentation.
Flavour: - It shall conform to the designated flavour. It shall have no off flavours and visible
sediment.
Specification:
Cream plug - absent

Sediment - absent
Fat % Min. - 1.5
T.S. % (Min.) - 17.2
TA (as lactic Acid) - Max. 0.17
Incubation Test at 37 C
a) pH variation of 7 days incubation max - 0.3

b) T.P (variation of 7 days incubation) - 0.02
c) Bulging Test Negative
Fat Determination
- Take 10 ml Sulphuric Acid into a butyrometer by means of

automatic measure
- Warm to 40 C and cool to 27 C
- Mix well
- Allow to stand for 3-4 minutes
- Transfer 10.75 ml of sample into butyrometer
- Add 1 ml amyl alcohol into butyrometer
- Close the butyrometer
- Transfer to 65 + 2 C water bath for 5 min.
- Centrifuge the butyrometer for 4 min.
- Take out butyrometer into water bath for 65 + 2 C and allow
the butyrometer to stand for not less than 3 minutes
- Take down the reading
Acidity
- Switch on the instrument

- System test will appear
- Wait for some time
- Check user method (3)
- Screen will show - recall method, store method, delete method
- Use recall method by putting cursor on it
- Press enter
- Select the program milk using the forward/backward key
- Press enter and the milk program will appear
- Put beaker having 10 gm of milk and 40 ml distilled water
- Stir using magnetic stirrer
- Dip the electrode and dispenser and press screen
- Acidity will come automatically on the screen
- After completion switch off the instrument
Total Solids
Gravimetric Method
Apparatus: Shallow flat bottom dishes of aluminum alloys, nickel, stainless steel, porcelain
silica, 7-8 cm diameter, about 1.5 cm in height and provided with easily removable and
closely fitting lids.
Procedure
- Weigh accurately the clean dry empty dish with the lid, pipette into
the dish about 5 ml of the prepared sample of milk and weigh quickly
with the lid on the dish.
- Place the dish uncovered on a boiling water bath
- Keep the base of the dish horizontal to promote uniform drying and protect it from
direct contact with the metal of water bath.
- After at least 30 min. remove the dish, wipe the bottom and transfer it to a well
ventilated oven at 98 - 100 C placing the lid by the dish
- The dish shall not be placed near the walls of the oven
- After 3 hours cover the dish and immediately transfer to a desiccators
- Allow cooling for about 30 min and weigh
- Return the dish uncovered and the lid to the oven and heat for 1 hr.
- Return to the desiccators - cool and weigh as before
- Repeat if necessary until the loss of weight between successive weighing does not
exceed 0.5 mg. Note the lowest weight
TS (% by weight) = w x 100
W
w = weight in gram of residue after drying

W = weight in gram of prepared sample taken for test.
BUTTER OIL
Specification
Moisture % - 0.5 max.
FFA - 0.3 max.
BR - 40-44 max.
Peroxide value- 0.8 max.
Sampling
Select 4/5 drums possible of different batches from each truck; clean the dust and
foreign matter from sampling point of the butter oil drum. Note down the source, lot number
and date of manufacture. Record these in B.O. testing register.
Break open the seals with a hammer and open the drums using the opening tool. Take
a composite B.O. sample from all drums in sterilized glass bottle using a sterilized trier in
case the butter oil is hard. Melt at 40-45 C and mix before going for analysis.
Moisture
Clean the dish. Dry in oven for 100 + 1 C for 1 hour. Allow cooling to the room temperature
in desiccators and weigh the dish. Weigh accurately 3-4 gms of B.O. sample. Place in water
bath for 20 min. Transfer to over 100 + 1 C and keep for 90 minutes. Allow the dish to cool
in the descicator and weigh.
Moisture = 100(W1-W2)/(W1-W)
W1 = Weight of dish with butter oil before drying

W2 = Weight of dish with butter oil after drying
W = Weight of empty dish
Free Fatty Acids
Take 10 gm of butter oil in 250 ml conical flask .Add 50 ml neutralized rectified spirit and
heat to boiling. Titrate against N/10 NaOH using phenolphthalein indicator.
FFA = (V x 2.82)/W
V = Volume of NaOH, W = Weight of sample.
Peroxide value
Using Photo Electric Colorimeter
- Switch on the instrument
- Check the switch. It should be at % T position.
- Put blacks plastic cuvette inside the hole and close the lid.
- Set zero by rotating the Knob 'set zero' so that 0.00 comes on
the screen
- Put the glass distilled water in glass cuvette and by rotating 'set
100 knob' and make the reading 100 on screen
- Change the switch from %T position top OD position and see

that the filter should be at a number 5 i.e. 550nm. Put the prepared fat
blank in glass cuvette in place of glass distilled water and again set
zero by rotating 'set zero' knob.
Put the reagent blank and note the OD of reagent blank check OD of the prepared test.
Subtract reagent value from the test samples and note the reading and then calculate
the peroxide value as below.
Testing
Transfer with a warm pipette 0.5 gm of B.O. in a test tube.

Pipette 9.3 ml CHC13 and CH3OH solvent in a test tube. Add 1 drop of NH4CNS
and one drop of FeCI2 solution and mix well. Make 2 blanks, one reagent blank
containing no B.O. and the other a fat blank containing fat NH4CNS and no FeCl2
solution. Mix well and keep the test tubes for 5 minutes and then measure optical
density at a wavelength of 550 nm.
Calculate peroxide value
Peroxide value = mg. Of Fe/10 ml solution

Wt.Of Sample x 55.84
BR Value
Same as in butter.
TOTAL DISSOLVED SOLIDS IN WATER
TDS is found by using an EC-TDS analyzer at a temperature of 25 C.
Salient features
- Microprocessor based
- Menu driven user friendly
- Auto ranging
- Measures directly the electrical conductivity and total dissolved solids
- Can be used for both aqueous and non-aqueous solution.
Description
EC-TDS analyzer is a microprocessor based analytical instrument for easy and quick
measurement of electrical conductivity in leg sample.
A constant AC potential is applied to segment of solution between platinum electrodes and

the electrical resistance and through it the conductance is measure. The platinum electrodes
are coated with platinum black to increase the surface area and to reduce the polarizing
resistance.
Similarly the TDS is also found out.
Principle of operation:
Solutions of electrolytes conduct the electric current by migration of ions under the influence
of electric field following Ohms law as electrons in the metallic conductors. Thus for an
applied EMF, maintained a constant but exceeding the decomposition voltage of electrolyte.
The current will vary inversely within the resistance or directly with the conductance of the
solution.
The electrical conductance is a summation of contribution from all the ions present in the unit
volume of the solutions and the velocities with which the ions move under the influence of
the EMF.
The conductivity of the electrolyte is temperature dependent i.e. proportional to the

temperatures rise at a rate of 2% per degree of most ions.
DETECTION OF Na AND K CONTENT USING FLAME PHOTOMETER
Preparation of working solution and milk sample
Stock solution of 1000 ppm for Na.
Dissolve 1.9070 gm. KCl in 1 litre of glass-distilled water.
Working solution
Take 1 ml of stock solution separately for Na and K in 100 ml volumetric flasks and make the
volume to 100 ml by adding glass-distilled water.
Preparation of sample: - Take 0.5 ml of well mix sample in 50 ml volumetric flask and make
volume to 50 ml by adding glass-distilled water.
Operational Procedure
Flame photometer is having 3 units
Compressor
Flame photometer burner
Digital FPM
- Connect all the three units as per instructions given by supplier
- Attach the cooking gas cylinder to the flame photometer carefully
- Switch on the compressor and adjust the pressure to 0.5 kg/cm2 by

rotating air knob, which is fixed on photometer.
- Open the lid of the burner and release the cooking gas simultaneously
and ignite the burner and adjust the flame by rotating the knob till the clear
blue zone flames comes and close the lid of burner.
- Select the desired filter Na+ and K+ that is fixed on the left side of the
flame photometer
- Switch on the digital FPM unit. It will display some digits on screen.
- Adjust the zero by using the knob 'set zero' of the FPM unit.
- Put a beaker of glass-distilled water below the sippon tube of the flame
photometer and again adjust zero. After zero adjustments, remove the distilled
water beaker. Put the sippon tube in desired Na+ or K+ working solution and
adjust 100% transmittance. Adjust 100% by rotating set zero 'coarse knob'
Instrument is ready to use. Put the prepared sample for analysis. Before testing the
sample confirm that the required filter of Na+ or K+ is selected. Reading on digital FPM
corresponds to mg/100 ml of Na+ or K+ in milk.
BACTERIOLOGY
Purpose- To ensure that the bacterial quality of milk and ice cream manufactured by
Mother Dairy conforms to standards.
Assessing Sterility of plant and equipment
1) Swab sample is taken over a 900-cm2 area of the equipment and sterility
tested.
2) Desired dilution is prepared from swab sample and plated for SPC
Collection of samples for micro-biological testing of milk
1) Four raw samples from different federations .15 dispatch milk tankers, 4
return milk tankers are tested weekly for SPC.
2) Butter is sampled aseptically and testing is done for coliform, yeast and
mould.
3) Milk powder: - SPC and coliform
4) Ice Cream
 Sterility tests in a month by taking samples from different process

equipments like storage tank freezer pipelines, flavour and ageing tanks
and filling machine nozzles.
 Mix samples are tested for SPC and coliform once a month if produced
during that period.
 Ice cream, kulfi and ice candies samples are tested for SPC and coliform
Bacteriological test at milk shop, retailer tanks and container mounted on rickshaw:
1) Swab/rinse samples are collected from milk shop/retailers tank and tested for
sterility
2) Milk samples from the above tested for SPC and coliform
3) If the bacteriological results are not within MD norms, a report is sent by QA &
QS department to the concerned department for corrective action. After taking
corrective action send the same report to QA & QS for repeating the
bacteriological tests results after confirmation are sent to concerned departments.
4) Milk samples and water samples from milk shop/retailer tanks/container mounted
on rickshaw are tested for SPC and coliform.
COMPOSITION AND PREPARATION OF MEDIA
Plate Count Agar
Ingredients:
Tryptone - 5 gm /1 litre
Glucose - 1 gm /1 litre
Yeast salt - 2.5 gm
Agar - 15 gm
Final pH - 70
Suspend 23.5 gm of ready-made P.C. agar in 1000 ml distilled water. Add 6.5 gm
NaCl dissolve and adjust the pH.7. Boil to dissolve the medium completely and fill it
in flasks or bottles.
Sterilize in autoclave:
VRBA
Peptone - 7 gm
Yeast - 3
Lactose - 10
Agar - 15
NaCl - 5
Neutral red - 0.03 gm
Crystal violet - 0.002 gm
Final pH - 7.4
Bile Salt - 1.5 gms
Suspend 41.5 gms ready made VRBA in 1000 ml distilled water. Heat to boiling to
dissolve agar completely. Do not boil for more than 2 minutes. Do not autoclave.
Cool it in water bath at 4.5 C before pouring in plates
BGLB 2% for PCT
Bile 20 gm
Lactose 10 gm
Peptone 10 gm
Brilliant green 0.0133 gm
Final pH 7.2 + 0.2
Preparation: Suspend 40 gm of readymade media in 1000 ml distilled water, warm slightly

to dissolve completely. Adjust the pH 7.2 + 0.2. Dispense 10 ml into culture tubes/test tubes
with inverted Durham's tube. Cap or plug the tubes. Sterilize.
PREPARATION OF DILUTION
Preparation of phosphate buffer
Dissolve 3 gm of KH2PO4 in 500 ml; distilled water. Adjust pH 7.2 with NaCl.
Make up to one liter volume with distilled water.
Preparation of batch dilution plank
Take 1.25 ml stock phosphate buffer solution and make up the volume to one litre
with distilled water.
Put it in dilution tubes or bottles so that after sterilization each will contain 9 ml in
dilution tube or 99 ml in dilution bottle. Sterilize in autoclave.
SPC
Material required:
1) Plating chamber
2) Petri dishes
3) Plate count agar
4) Auto pipette tip (1.0 ml)
5) Dilution tubes containing 9 ml of batch phosphate buffer solution
Procedure
1) Transfer 1 ml of well-mixed samples to 9 ml dilutent (phosphate buffer

solution). Mix well. Transfer 1 ml of the suspension to second tube to make
second dilution. Similarly make 2nd or 3rd dilution as per requirement.
2) Arrange 2 petri plates for each dilution to be tested. Mark them with sample
number and date.
3) Transfer 1 ml in each plate from respective dilution of sample being tested.
4) Melt the P.C.A. Cool it to about 45 C and pour 10-15 ml of this medium into the
petridishes. Mix the agar by rotating plates.
5) Allow the agar to set invert and incubate the plates at 37 + 1 C for 48 hours.
6) At the end of 48 hrs. Remove the plate from the incubator and count the colonies.
7) Also prepare a control plate with 15 ml media for checking its sterility
Counting and expression of results
Count the colonies grown in petri plates. Count only those plates, which have 30-300
colonies
Computation
Count the colonies developed in each plate for respective dilutions. Multiply colonies
per plate by dilution used and report the arithmetic average as plate count per milli-
litre/gram.
Recording/reporting of results
Record and report the result as SPC/ml/gm

COLIFORM TEST FOR MILK
1) VRB agar
2) Auto pipette with tips
3) Dilution Blank
4) Petri dishes
Procedure for solid media
1) Transfer 1 ml of well mixed sample to 9 ml dilutent/phosphate buffer solution and

use well to make first dilution .If required make second dilution by transferring 1
ml of first dilution into 9 ml dilutent
2) Arrange 2 petre plates for each sample. Mark them with sample number and date.
3) Transfer 1 ml in each plate respective dilution of the sample to be tested.
4) Add 10-15 ml of VRB agar previously melted and cooled to about 45 C.
5) Mix the contents thoroughly by rotating the plates and allow the agar to solidify.
Pour additional approximately 5 ml of the media over the surface of the solidified
medium and allow the solidify again.
6) Invert the plates and incubate the plates at 37 + 1 C for 18-24 hours.
Counting and expression of results
Count dark red colonies measuring at least 0.5 mm in diameter.
Computation – count dark red with red precipitate colonies measuring at least 0.5 mm
in diameter in each plates, for each dilution plated. Multiply colonies per plate by
dilution used and report the arithmetic average as coliform count …/ml/gm of
product.
Recording: Record and report as coliform count....../ml/gm of product.

TEST OF COLIFORM BACTERIA BY LIQUID MEDIA (PCT)
Materials required
Auto Pipette with tips
Brilliant green bile broth
Procedure:
Transfer 1 ml from first dilution of sample into BG Bile broth in 2% tube in

triplicate. Incubate for 48 hrs at 37 + 1 C and observe for acid and gas production.
Production of gas and opacity in at least two tubes out of 3 constitutes the positive
presumptive test.
PCT is positive and simultaneously typical colonies observed on solid media. This
confirms the presence of coliform in the sample. If required further confirmation may
be done using streak techniques on EMB agar or microscopically
ASSESSING STERILITY
Materials – Swab tube, cotton wool, 30 cm long SS wire, phosphate buffer/saline

(0.9% NaCl) and distilled water.
Swab sampling: Press the sterilized swab with rolling motion against the side of glass
tube removing excess liquid and take it out of the tube. Rub the swab with the
pressure back and forth over the area to be examined so that all the parts of the
surface treated twice and for plain surface 900-cm2 areas covered for swabbing over
required areas. After scrubbing the required area return the swab to the solution in the
tube. Allow the swab to be immersed in the liquid for five minutes and mix by
swirling the swab vigorously in the solution 5-6 times. Remove the swab by pressing
against the side of the test tube.
Swab testing
Mix the solution thoroughly by rotating the tube between the palms of the hands.
Using 9 ml dilution blank prepare Ist dilution of the sample and proceed as per standard
plate counts in duplicate plates and add 10-15 ml plate count agar medium and incubate
at 37 + 1 C for 48 hours.
COMPUTATION
Multiplication factors for sterility counts
Milk Plant
Silo surface - 300
Pipeline Dairy (72 mm) – 400
Pipe line (filling) – 290
Tanker valve (72 mm) – 400
Hose Pipe (35 mm) - 810
Tanker inside - 300
Ice Cream Plant
Aging Plant surface - 300
Mixing vat surface - 300
Flavour tank - 300
Aging tank valve - 770
Flavour tank valve - 575
Pipeline - 770
Vending Outlet
OHT - 100
CIP Tank - 100
Side tank - 100
Pipe Line - 270
Beaker -2
BUTTER YEAST & MOULD
Preparation of test portion
Soften butter and mix thoroughly and weigh aseptically 11 gm butter in 99 ml

sterilized diluent previously warmed at about 45 C to make first dilution. Transfer 1
ml of first dilution into tube containing 9 ml sterilized dilutent to make second
dilution. Similarly prepare third and 4th dilution as per requirement.
Procedure of plating
2) Select 2 consecutive dilution of samples to plate
3) Arrange 2 petri plates for each dilution. Mark them with sample number, date and
dilution factor
4) Transfer 1 ml in each plate in respective dilution of the sample.
5) Melt the chloramphenicol agar, cool it to about 45 C and pour 10-15 ml into the
petri dish, Mix the agar by rotating the plates.
6) Allow the agar to set, invert and incubate the plates at 25 + 1 C for 5 days. If
moulds grow fast and develop into large colonies, plates may be incubated for 3
days only.
7) Count the number of colonies grown in each plate and compute the result. Also
prepare a control plate with 15 ml media for checking the sterility.
Counting and computation of yeast and mould colonies to express results.
Counting- Count the colonies grown in two consecutive dilutions in petri plates.
Count only those plates, which have 15 – 150 colonies.
Calculation for result – Calculate the number of yeast mould/gm of butter using the
following equation:
N = ΣC
(n1 + 0.1n2)d
C = sum of colonies counted on all petri plates
n1 = Number of plates on first dilution
n2 = Number of plates in 2nd dilution
d = Dilution factor corresponding to the first dilution.
Round the result calculated to two significant figures. The result shall be expressed as
a number between 1.0 and 9.9 multiplied by 10x where x is the appropriate power of
10.
If there were no colonies on plates the number of yeast and mould per plate should be
reported as less than 1.
OIL LABORATORY
Oil laboratory deals with complete testing of oil. It is a NABL accredited laboratory.
Laboratory mainly deals with the testing of different varieties of ‘Dhara’ refined oil.
Here the following tests are being performed
1) Physical characteristics
a) Determination of smoke and flash point (closed cup method)
The method determines the temperature at which sample will flash when a test
flame is applied under the conditions specified for the test.For this fill the cup
with oil upto the mark.suspend and secure thermometer in a vertical position
half way between the centre and back of the cup. Heat the sample gradually to
250 degree centigrade and occasionally check the flame.
b) Detection of coal tar oil soluble colour in edible oils.
This test is performed to see, if any, presence of coal tar dye in oil. The
principle of the test is that the petroleum ether solution of oil sample gives
different shades of colour with different concentrations of HCL in the
presence of coal tar
2) Chemical Characteristic
3) s
a) Saponification value:
Saponification value is the number of mg of potassium hydroxide required

to saponify 1 gram of oil or fat. Here the oil sample is saponified by
refluxing with a known excess of ethanolic potassium hydroxide solution.
The alkali required for saponification determined by titration of excess
potassium hydroxide with standard HCL.
APPARATUS
250ml conical flask,1 m air condenser,Hot water bath/Hot plate
REAGENTS
Ethanolic KOH solution,Ph indicator,Std. HCL(0.5 N)

PROCEDURE
Weigh 2 gm of dry sample in the flask. Pippette 25 mlof alc. KOH into the
flask.conduct a blank sample with this.Warm till saponification is
complete.Cool it and titrate the excess KOH with std HCL using ph.
Indicator.
SAPONIFICATION VALUE= 56.1(B-S)N/W
B= Vol of std HCL required for blank
S= Vol of std HCL required for sample.
N=Normality of the HCL taken
W= Wt. Of the oil taken for test.
b) Unsaponification value :
Here the fraction of substances in oils and fats, which is not saponified by
caustic alkali, is determined. The basic principal involved here is that the
substances which is not saponified and soluble in ordinary fat solvents are
extracted the unsaponifiable matter determined. It mainly includes sterols,
higher aliphatic alcohols, pigments, vitamins and hydrocarbons.
c) Iodine value
The iodine value of an oil/fat is the number of grams of iodine absorbed by

100 gm of fat. When determined by using Wijs solution.
The main principal involved is that oil/fat sample taken in CCl4 is treated
with known excess of iodine monochloride solution in glacial acetic acid
solution. The excess of iodine monochloride is treated with KI and the
liberated iodine established by titration with sodium thiosulphate solution.
The iodine value is a measure of the amount of unsaturation in a fat.
d) Acid Value :
Acid value is defined as number of mg of KOH required to neutralize the
free fatty acid present in 1 gm of fat. The value is also expressed as
percent of free fatty acids calculated as oleic acid.
The acid value is determined by directly titrating the oil/fat in an alcoholic
medium against standard KOH/NaOH solution.
The value when expressed as percentage of free fatty acids is calculated as
Oleic, Lauric, rein oleic or palmitic acid.
APPARATUS
250 ML conical flask
REAGENTS
Ethyl Alcohol, Phenopthalin indicator, Std aq. KOH/NAOH solution
PROCEDURE
Mix oil .Weigh 2-2.5 gm of the sample.Add 50 ml –100ml freshly
neutralized hot ethyl alcohol and 1 ml phenopthalin. Boil the mixture for 5
min. Titrate while hot against std alkali solution shaking vigorously.Vol of
alkali used should not exceed 10 ml.
ACID VALUE= 56.1VN/W
V= Vol of KOH used
N= Normality of KOH used
W= Wt. In gm of sample.
3) Identity tests
1) Detection of sesame oil (baudouin test)

The development of pink colour with furfural solution in the presence of
HCl indicates the presence of sesame oil.
2) Detection of cottonseed oil
The development of red colour on heating the oil with a solution of sulphur
in CS2 indicates the presence of cottonseed oil. The test is also given by
hempseed oil and fat containing cyclopropenoid fatty acids.
3) Detection of linseed oil (Hex bromide test)

The oil in chloroform is treated with bromine and then with alcohol and
ether in cold conditions indicates that the linseed oil is present in the oil
4) Detection of groundnut oil (Belier turbidity temperature test)

Oils containing long chain saturated fatty acids give a precipitate at a
particular temperature which is specific for the oil when their alcoholic soap
solution is treated with dilute acetic acid and 70% ethyl alcohol.
4) Detection of Adulterants
1) Mineral Oil Test

The presence of mineral oil is indicated by the development of turbidity
when hot distilled water is added to freshly made alcoholic solution of the
soap formed by the oil.
Here oil is first saponified with .22 ml alcoholic KOH boiled in a water bath
and then 25 ml of boiling distilled water is added.Turbidity indicates the
presence of mineral oil.
2) Rancidity
Shake 5 ml of the oil vigorously with 5 ml of 0.1% phloroglucinol solution
in diethyl ether and 5 ml of concentrated HCl for 20 seconds. A pink colour
indicates incipient rancidity
3) Argemone oil (TLC)
Principle: The hydrochloric acid extract of the oil sample containing

argemone oil when subjected to TLC for the separation of alkaloid gives
fluorescent shots under UV light.
4) Castor oil (TLC)
Triricinolein a characteristic and predominant triglyceride component of

castor oil is separated on silica get TLC and visualized by Iodine vapors.
5) Mineral oil (TLC)
Being non-polar mineral oils gives faster moving spots on TLC plates than
the triglycerides.

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INDEX

1. Introduction to industrial training, Purpose and objective of training

 To operate, procure, process and market milk and milk products.

 Production of good milk after its qualitative and quantitative

 System to eliminate middleman.

 Providing technical inputs and services to yield of milch animals.

 Organizing an efficient transport system to collect milk from

 Set up of balancing dairies and storage system to convert excess milk

Our commitment is to excellence. The evolving needs of our customers

To ensure that we are second to none:

• We maintain a vibrant work environment that encourages excellence.

We shall constantly strive to be leaders in the dairy industry in Delhi, in

We are committed to be a leader in Dairy Industry in India by being a benchmark

We shall continue to improve our environmental performance by :-

• Adopting processes, procedures and systems for

National Accreditation Board For Testing And Calibration Laboratories (NABL),

We shall create an environment where employees feel happy to work.

Through innovation, consistent learning and continuous improvement, we shall achieve

MOTHER DAIRY MISSION:

- Anise (diasterase) Starch

Role of milk in human life

 1 Liter of Cow’s milk gives 720 Calorie (3000J) of energy.

Most milk is composed of 80 to 90 percent water. The remaining 10 percent

Homogenization of the ice cream mix is essential. The main purpose of

• It prevents fat separation during ageing

Proper pasteurization destroys all pathogenic or disease producing bacteria, thereby

Aging the mix

i) It improves the body and texture of ice cream

Making the mix

Fruit Feeder machine

Packaging & Storage( at -25 to -50C)

Preheated (35 to 40OC).

At 40 OC, add whey protein concentrate

Heating (65 to 70 OC)

Add stabilizer and Emulsifier

After dissolved the sugar add white butter.

Flow Diagram of kulfi mix

Preheated (35 to 40OC).

At 40 OC, add whey protein concentrate

Heating (65 to 70 OC)

Add stabilizer and Emulsifier

After dissolved the sugar add white butter.

Mix transfer Pump

Continuous Freezer (-4 to -5 OC)

Fruit Feeder Machine

MOTHER DAIRY - ICE CREAM PLANT

 Temperature of Ageing tank: 7±20C.

 Mix Preparation Vat: 3

 Ageing Tank No.1

 Ageing Tank No.2

 Ageing tank No. 3

 Ageing tank No. 4

 Raw milk Tank

 Ageing tank No. 5

 Ageing tank No. 6

 Ageing tank No. 7

 Ageing Tank No. 8

 Ageing Tank No. 9

Machine type: OMO-1000

 Butter Melting Kettle:

 Cane syrup tank:

 Cone Chocobar tank No. 2

 Chocolate tank No.:1