MOTHER DAIRY

REPORT ON PRODUCTION PROCESS OF MILK IN MOTHER DAIRY

PATPARGANJ, NEW DELHI

OVERVIEW OF THE COMPANY
Mother Dairy – Delhi was set up in 1974 under the Operation Flood Programme, a wholly
owned subsidy of the National Dairy Development Board (NDDB), whose current chairman is
Dr. Amrita Patel. The company markets more then 2.2 million litres of milk daily in Delhi and
surrounding areas of Western U.P. and Haryana, Mumbai and Hyderabad. Mother Dairy Mill has
a market share of 66% in the branded sector in Delhi where it sells 2 million litres of milk daily
and undertakes its marketing operations through more then 10,000 retail outlets. The atmosphere
of the industry is very calm and health and is rich in various varieties of flora. Mother Dairy is
one of the largest liquid milk plants in Asia. Mother Dairy sources its requirement of liquid milk
from dairy co-operatives and producer institutions.
Mother Dairy’s objective is to:

(a) Ensure that milk producers and farmers regularly and continually receive market prices by
offering quality milk, milk products and other food products to consumers at competitive prices.
To ensure this Mother Dairy operates such that the farmer gets 85% of the total cost of sales.

(b) Uphold institutional structures that empower milk producers and farmers through processes
that are equitable.

At Mother Dairy, processing of milk is controlled by process automation whereby state-of-the-

art microprocessor technology is adopted to integrate and completely automate all functions of
the milk processing areas to ensure high product quality/ reliability and safety.
In addition to its market leadership in India, Mother Dairy is also active in the global arena,
exporting its range of dairy products to various international markets. Mother Dairy is an IS/ISO
9002, IS 15000 HACCP and IS 14001 EMS certified organization. Moreover, its Quality
Assurance Laboratory is certified by National Accreditation Board for Testing and Calibration
Laboratory (NABL)-Department of Science and Technology, Government of India.

Management System Policy Of The Company

Their commitment is to excellence. The evolving needs of their customers drive them to
continual improvement in their processes and systems. They are committed to:
 Apply state of the art technology and processes to enhance productivity that ensures
quality at a competitive price.
 Apply processes to clean production, pollution prevention and optimize resources
utilization in all operations.
 Follow food safety management system and apply HACCP (Hazard Analysis Critical
Control Points) principles to provide safe products to customers.
 Develop and empower own people for maintaining a vibrant working environment, which
encourages excellence.
 Company with appreciable regulations and legislations.

They pledge themselves towards providing quality and safe products under clean and hygienic
environment.

PRODUCT RANGE

BRAND NAME TYPE OF PRODUCT ITEMS

MOTHER DAIRY Milk and its product Packaged Milk (Full Cream,
Standardized, Toned, Double
Toned Skimmed and Probiotic),
Butter, Dahi, Ghee, Cheese, Ice-
Creams, UHT Milk, Lassi &
Flavoured Milk.
SAFAL Fresh and frozen fruit and Fruits, vegetables, rice processed
vegetable products item (jams, juices, ketchup, pulp,
etc.)

DHARA Edible oil Refined Vegetable Oil, Refined

Soybean Oil, Refined Sunflower
Oil, Refined Rice Bran Oil,
Kachi Ghani Mustard Oil and
Filtered Groundnut Oil.
Mother Dairy's range of products include the brands Mother Dairy (milk, milk products, curd, ice
cream, butter, dairy whitener etc), Dhara (range of edible oils) and Safal (range of fresh fruits
and vegetables, frozen vegetables, fruit juices).

Mother Dairy Foods Processing Ltd offers the following products: Mother Dairy markets dairy
products like Liquid Milk, Ice Creams, Flavoured Milk, Dahi, Lassi, Mishti Doi, Ghee, White
Butter, Table Butter, Cheese, SMP, Dairy Whitener, UHT Milk, Dhara range of edible oils and
the Safal range of fresh Fruits & Vegetables, Frozen Vegetables and Fruit Juices at a national
level, through its sales and distribution networks, for marketing food items. Mother Dairy milk
(Bulk Vended Milk) is fortified with vitamin A @2000 IU per litre of milk as a part of social
accountability. This program was started with the Mother Dairy, Delhi, since February 1980and
there after Mother Dairy is continuing this program on their own as a social responsibility
without having any financial assistance from the Government as well as since it is felt that BVM
is generally consumed by the middle / lower middle / poor strata of the society. It is also found
that the dietary practices adopted by these classes are deficient in Vitamin A. Mother Dairy
sources significant part of its requirement of liquid milk from dairy cooperatives. Similarly,
Mother Dairy sources fruits and vegetables from farmers / growers associations. Mother Dairy
also contributes to the cause of oilseeds grower cooperatives that manufacture/ pack the Dhara
range of edible oils by undertaking to nationally market all Dhara products.

AVAILABILTY OF PRODUCTS IN MARKET

Packaged MILK is available in 5 different varieties
1. Full Cream milk - milk fat 6%, SNF 9%

2. Standardised milk - milk fat 4.5%, SNF 8.5%

3. Toned milk - milk fat 3%, SNF 8.5%

4. Double toned milk - milk fat 1.5%, SNF 9%

5. Skimmed milk - milk fat 0.5%, SNF 8.7%

Other than packaged milk, Bulk Vended Token Milk is also available which is distributed
through vending machines installed in different regions of the city.

The high quality variant of milk is also available under the brand name ok ‘MILK’. It is thick &
completely natural, containing no preservations. It is referred with name of UHT (Ultra Heat
Treatment) Milk.

Mother Dairy also manufactures flavoured milk under the brand name of ‘CHILLZ’. It is
available in three flavours namely Kesar, Elaichi, Vanilla and Chocolate flavour.
Various MILK products offered by Mother Dairy
Various milk products of Mother Dairy are:

1. Mother Dairy Ghee

2. Mother Dairy Butter

3. Mother Dairy Cheese

4. Mother Dairy Dahi (Curd)

5. Mother Dairy Lassi

Except all these milk products Mother dairy also manufactures Ice Cream under two
categories namely CHILLZ and Mother Dairy Ice Cream.

PROBIOTIC
It is the latest product range launched by Mother Dairy. It mainly contains BB-12 friendly
Bacteria which results in better digestion and absorption of nutrients. It also contains probiotic
fibre which also results in better digestion. The various products in this category are:

1. b-Activ Probiotic Dahi

2. b-Activ Probiotic Lassi

3. b-Activ Curd

4. Nutrifit (Strawberry & Mango)

SAFAL
Range of fresh foods & vegetables, frozen vegetables, fruit pulps and fruit juices etc.

DHARA
It has a popular range of edible oils in different types as refined soya bean oil, refined sunflower
oil and filtered ground nut oil etc.

MILK PROCESSING PROCESS

Milk brought from regional collection centres
through insulated milk vans/trucks.

Milk is then tested on 15 quality standards

and is then stored in refrigerated silos
(vertical containers).

Milk is then heated and is then

‘Clarified.’ The Clarifier spins out
(centrifugal force) the physical impurities
present in the milk.
As the milk originates from different
animals it is ‘Standardized’ i.e. the
total fat and SNF percentages are
brought to desired levels as per the
prescribed norms.

Milk is then ‘Homogenized.’ In this

process the large fat globules are broken
into tiny fat molecules thus, giving milk a
uniform consistency and making it whiter in
appearance.

Milk is then subjected to the process

of ‘Pasteurization.’ The milk is first
heated to 75°C for 15 seconds and
Milk is then fortified with various
then is rapidly cooled to 4°C thus
Vitamins and Minerals depending on
killing all the pathogens in the milk,
the type of milk. It is then sent back
without disrupting the taste and
to the silos or packaged.
nutritive content.
Milk Procurement
Milk is received through insulated road/rail tankers at a very low temperature thus retaining its
freshness. The milk then undergoes more than 15 stringent quality tests before it is stored in
silo’s (vertical milk storage tanks) for further processing. Mother Dairy sources its requirement
of liquid milk from dairy co-operatives and producer institutions. The Operation Flood
programme helps both farmers as well as the city consumers. The programme ensures that the
farmers get a fair price for their cow & buffalo milk and the consumers get best quality milk at
reasonable prices. Milk is received from farmer cooperatives through insulated road/rail tankers
at very low temperature in order to retain its freshness.

Milk Distribution
79 tankers in the morning and 75 tankers in the evening bring in milk from the regional
collection centres. After collection the same tankers are utilized for the delivery of the processed
milk to the vendors and outlets. Mother Dairy has over 820 Milk Distribution Outlets in the

National Capital Region. Each of these outlets place their demand by raising an invoice one day
in advance. The demand is also calculated using the ‘Calendar’ Scheme, in this depending on the
pre-calculated seasonal demands the outlets place their orders accordingly. In order to satisfy
immediate demand, 20 to 25 tankers are provided with a buffer stock of 500 litres each day so
that they can be mobilized to cater the demand in an area. To coordinate its operations all the
tankers are equipped with HAM radios.

Distribution Channels:

a) Token Distribution: Also, termed as “Lohe ki bhains” (metal buffalo), is an automated

milk vending machine.

b) COW: Container on Wheels or COW is a manual milk distribution program in which

cycle-rickshaws are employed for milk distribution.

c) Retailers: The packaged milk is distributed via the retailer network throughout the city.

Processing Of Milk
At Mother Dairy, processing of milk is controlled by process automation whereby state-of-the-
art microprocessor technology is adopted to integrate and completely automate all functions of
the milk processing areas to ensure high product quality/ reliability and safety. Mother Dairy is
an IS/ ISO-9002, IS-15000 HACCP and IS-14001 EMS certified organization. Moreover, its
Quality Assurance Laboratory is certified by National Accreditation Board for Testing and
Calibration Laboratory (NABL)-Department of Science and Technology, Government of India.
Also here, the processing of milk is done through state-of-the-art microprocessor technology
which integrates and completely automates all functions of milk processing and ensures high
product quality, reliability and safety. The various stages of milk processing are given below :

Clarification
The chilled milk from the silos goes to the clarifier after pre-heating. The clarifier spins the milk
at a very high speed, removing all dust particles that are invisible to the naked eye.

Standardization
Milk from different breeds of cows and buffaloes varies in its composition, it is standardized by
raising or lowering its fat and SNF percentage to a desired level, so as to deliver the milk to
consumers as per prescribed PFA norms.

Homogenization
In the process, the milk is subjected to a very high pressure due to which the large fat globules
present in the milk are broken into tiny droplets. The milk fat gets evenly distributed and milk
appears whiter and thicker. Milk is homogenized for consumers who do not like creamy layer on
the top. Homogenization improves palatability of milk.

Pasteurization
In this process, the milk is heated at 72 degrees for 15 seconds and then is rapidly cooled down
to 4 degrees. This process kills all the pathogenic bacteria present in the milk making milk safe
for consumption. Pasteurization unlike boiling does not effect affect the nutritive value of the
milk.

Pasteurization, named after French Scientist Louis Pasteur who invented the process was first
applied to milk by Dr. Soxhlet of Germany.

Fortification With Vitamin ‘A’

Homogenized Toned Milk during processing is fortified with vitamin ‘A’. The deficiency can
lead to night blindness and skin horning.

Homogenisation
At Mother Dairy the milk is also homogenised. This ensures that the customers get uniform
amount of cream in their milk.

In this process the milk is pumped at a very high pressure turning the cream into tiny droplets
thus distributing the fat through out the milk. These droplets do not float to the surface to form a
creamy layer. That is why no creamy layer appears when Mother Dairy milk is boiled at home.

Mother Dairy shops sell homogenised toned milk which contains minimum 3% fat even though
you cannot notice it.

Ensuring Quality

After processing, milk is dispatched in hygienic and sterile milk tankers or packed in high grade
material and transported under cold chain to your nearest milk booth. Everyday, as part of
quality assurance process, milk samples are collected from milk shops randomly and are tested.
The above processes helps in maintaining stringent quality standards in order to ensure that the
milk you get is fresh, pure and healthy. Mother Dairy is an IS/ ISO 9002, IS 15000 HACCP and
IS 14001 EMS certified organization.
Mother Dairy, Delhi has been awarded ISO 9001:2000 (Quality Management Systems), HACCP,
2002 RvA (Food Safety Management Systems) and ISO 14001:2004 (Environmental
Management Systems) Certifications. Moreover, National Accreditation Board accredits its
Quality Assurance Laboratory as per ISO/IEC 17025:1999 for Testing and Calibration
Laboratories, Department of Science and Technology, Government of India.

Quality Control
Stringent quality control methodologies are employed in Mother Dairy.

a) The milk is tested for adulterations and quality at the time of collection from the farmers.
 b) The Milk that comes from the collection points to the Mother Dairy plant is ensured to
have a temperature of not more than 7°C and is subjected to 15 product and quality
checks.

c) The Milk quality is checked repeatedly after each processing phase and the temperature is
judiciously maintained less than 5°C always.

d) Before the milk leaves the plant for the delivery/distribution outlets the milk is tested
again.

e) The temperature of milk in the delivery trucks is always maintained less than 7°C.

f) All the trucks that deliver milk have specified guidelines to bring back 100 litres of milk
after distribution. This is done in order to test the delivered milk and to ensure that the
tankers are not adulterated during distribution.

g) Since all the employed processing procedures are automated, no contamination by human
hands takes place.

h) To ensure milk freshness the collection and distribution points are always chosen such
that the travel time between them is always less than 36 hours.

Distribution Of Mother Dairy Products :

Mother Dairy markets approximately 2.8 million liters of milk daily in the markets of Delhi,
Mumbai, Saurashtra and Hyderabad. Mother Dairy Milk has a market share of 66% in the
branded sector in Delhi where it sells 2.3 million liters of milk daily and undertakes its marketing
operations through around 14,000 retail outlets and 845 exclusive outlets of Mother Dairy.

The company’s derives significant competitive advantage from its unique distribution network of
bulk vending booths, retail outlets and mobile units. Mother Dairy ice creams launched in the
year 1995 have shown continuous growth over the years and today boasts of approximately 62%
market share in Delhi and NCR. Mother Dairy also manufactures and markets a wide range of
dairy products that include Butter, Dahi, Ghee, Cheese, UHT Milk, Lassi & Flavored Milk and
most of these products are available across the country.

The company markets an array of fresh and frozen fruit and vegetable products under the brand
name SAFAL through a chain of 400+ own Fruit and Vegetable shops and more than 20,000
retail outlets in various parts of the country. Fresh produce from the producers is handled at the
Company’s modern distribution facility in Delhi with an annual capacity of 200,000 MT. An IQF
facility with capacity of around 75 MT per day is also operational in Delhi. A state-of-the-art
fruit processing plant of fruit handling capacity of 120 MT per day, a 100 percent EOU, setup in
1996 at Mumbai supplies quality products in the international market. With increasing demand
another state-of-the-art fruit processing plant has been set up at Bangalore with fruit handling
capacity of around 250 MT per day.

Management System Policy

 1. Apply state of the art technology and processes to enhance productivity that ensures
quality at competitive price.

2. Apply processes for clean production, pollution prevention and optimize resource
utilization in all operations

3. Follow food safety management system and apply HACCP (Hazard Analysis Critical
Control Points) principles to provide safe products to customers

4. Comply with applicable regulations and legislations.

5. Mother Dairy pledge to provide quality and safe products under clean and hygienic
environment.

The following steps are taken and ongoing efforts are continuously made as per "Management
Systems Policy"-

 Minimize Waste generation

 Conservation of resources

 Use of renewable energy

 Recycling & re-use

As far as the environment management is concerned it has the following arrangements-

Solar Panels
In an effort to conserve fuel, Mother Dairy utilizes the solar energy to preheat the water going
into the boilers. This also minimizes the pollution caused by burning of fuels like coal.oil etc.

Rainwater Harvesting
For maintaining groundwater level it has installed the plant in the premises.

Effluent Treatment Plant

The water used for cleaning the equipment and tankers is treated at the effluent plant in the dairy
before being discharged into the sewage system.
Energy Management Policy

Mother Dairy Food Processing Ltd. commit themselves for optimum utilization of energy in all
manufacturing activities as well as in office by:

 Monitoring closely and controlling the consumption of various forms of energy through
an effective Energy Management System.

 All round participation of all employees and educating them about energy conservation.

 Maximum utilization of renewable energy sources.

 Upgradation of processes, technology and use of energy efficient equipments.

 Optimum utilization of plant capacity.

 As a part of energy conservation and environment protection commitments, reduce the

specific energy consumption.

As part of their energy conservation policy they saved Rs. 55 lakh of energy as per the current
data with the help of 1oo% participation from the employees.

They also have a Total Productive Maintenance (TPM) for distribution which says “to
eliminate accidents and breakdowns and increase the overall economic effect of all the resources
by developing a system to enhance the knowledge and skill of employees, thereby increasing
productivity and reducing costs.”The main policy which focuses the customer is the Service
along with Quality policy which states that the customer should be served in the best possible
manner and should also get the quality up to the mark.

Enhance Consumer Information

To raise the consumers awareness regarding Adulteration of milk, Mother Dairy has thrown open
its testing facilities. In its laboratories consumers can see for themselves how impurities and
adulterants are easily detected. Mother Dairy also has two "mobile labs" that can test milk in the
residential colonies. All this is part of a commitment to provide the consumers with the purest
milk nature has to offer.

PROCESS DESIGN AND PLANT LAYOUT

Regional milk procurement

centers

Milk procurement and

testing lab

Refrigerated storage silos

Clarification unit

Standardisation unit

Homogenization unit

Pasteurization unit

Milk fortification unit

Packaging unit

Refrigerated storage silos

 Ice cream manufacturing unit

Dairy product manufacturing

Sent to various distribution

network

The various departments in Mother Dairy Patparganj milk plant were:

1. Manufacturing Department

2. Production Department

3. MIS Department

4. Utility Department

5. Safety, Health & Environment Department

6. Thermal Department

7. Electrical Department

8. Automation Department

9. Procurement Department

10. Consumer Information Department

OBSERVATION DURING THE VISIT

The most important observation during the visit was the hygiene factor present there. The
premises and the plant area was clean, the employees have the orders not to touch milk with bare
hands and they get their machines and silos cleaned every weekend to ensure that the milk
produced is safe for the customers.

Moreover, they have a specific TPM (Total Productive Maintenance) policy for everything like
for distribution, energy conservation, environment etc. and KAIZEN policy for all the employees
which they have to follow.
They have these policies as strict code of conduct as they are manufacturing milk which requires
purity and hygiene and to give the best to the customers the company needs to do this. That is
why their policies can be seen at most of the places in the premises.

My Learning From The Visit

It was a very Fruitful trip not only from the industry point of view but also from the educational
point of view. We met an employee of the company who was working for the past 31 years of his
life and he seemed to be quiet happy by his commitment. Some of the questions that he answered
were an eye opener to us, like:
• How should milk be consumed?
• When should milk be consumed?
• Why milk is important to us?
• Why is it important to clear customer doubts?

Apart from these doubts that we all had in our mind he gave a Piece Of Mind regarding
Management and shared some of his learning from past 31 yrs of his life which in itself was a
great experience. He showed us a small presentation on How Mother Dairy has contributed
towards Operation Flood. All in all it was a wonderful experience to visit and observe a
corporate scenario for the very first time.