KATRAJ DAIRY

INTRODUCTION
KATRAJ DAIRY- PAST TO PRESENT
Katraj Dairy was incorporated in 1960 with an intension of
providing an organized facility of milk collection for the village level
farmers situated in Pune district. Katraj Dairy started with milk collection
of about 0.30 lakh (30.000) liters per day in the first year of operation and
today, has steadily grown to over 1.50 lakh (0.15 million) liters per day
and has a financial turnover of over Rs.150 crores (US$ 33 million).
Katraj Dairy has achieved ISO 9001:2000 & HACCP
certification from DNV in Oct. 2006 & maintained. In Oct. 2009 Dairy
has achieved ISO 9001:2008 & HACCP 2006 Dutch Standard from
Dr. Norskey Veritus.
Katraj Dairy with its eight chilling plants and 12 BMC spread
almost all over the district has an installed milk handling capacity of over
5 lakh (0.50 million) liters per day. The main plant of Katraj is equipped
with modern Pasteurizer, homogenizer, Cream separator, Ghee
processing, automatic packing of milk and milk products and other
quality testing devices and well equipped labs. Katraj Dairy has an
installed processing capacity of 2 lakh (0.2 million) liters per day.
Katraj dairy manufactures / Distributes milk and milk products
like Pasteurized/ Homogenized-Cow milk, Toned milk, Double toned
milk, Standardized Milk, Full cream milk, Cow & Buffalo Cream and
Ghee, Shrikhand, Amrakhand, Malai Paneer, Dahi, Flavored Milk, Lassi,
Jeera Tak, Table Butter, Milk Powder, Softy Ice cream, pedha, Khoa and
in the near future plans to introduce sterilized milk in 200ml bottle and
hard ice-cream with different flavors in different pack sizes.
All these products are available at Katraj owned parlors at
various locations in Pune City and through appointed distributors and
retailing circuits. Very soon, Katraj plans to introduce an online ordering
system for its distributors/ retailers and consumers.
Katraj products have been in use in thousands of homes in Pune
since 1961. Katraj Milk, Katraj Ghee, Katraj Shrikhand, Katraj
Amrakhand, Katraj Lassi, Katraj Jeera tak (buttermilk), Katraj cream
have made Katraj a leading food brand in Western Maharashtra. Today
Katraj is a symbol of high-quality milk products sold at reasonable prices,
the genesis of a vast co-operative network triumph of indigenous
technology, the marketing savvy of a farmers' organization.
OBJECTIVES OF KATRAJ DAIRY
The objectives of Katraj Dairy are, to build a valued chain of
farmers to source milk at an organized level, manufacture products at a
very high quality level and create a demand for their products in the
competitive market without having any reasons to be pointed at.
This organization has a unique advantage, its strategic location.
Based in Pune city, a place with historic, cultural importance and a major
district in Maharashtra, India. The city is known as the city of students
because of its large number of educational centers. Another major
advantage is that Mumbai is just 180km. away. Thus using these key
factors, they want to serve the state with their superior quality of milk.
They want the state to crave for this superior quality of milk.
THE FARMERS & KATRAJ DIARY
Prior to Katraj Diary, farmers use to sell their milk to
middlemen. These middlemen were never trust worthy as the farmers
milk was always adulterated with water, promises that were never
fulfilled, the true price at which the milk was sold was never known and
the farmers didnt get their money most of the time, if they ever got it at
all. Although the farmers didnt like this system, they didnt have a
choice, as there were no other alternatives.
However, as Katraj Dairy came along, a new picture was
painted. Katraj simplified this system to eliminate the problems of the
farmers and create a win- win situation for both of them. Katraj
strategically placed collection centers in the middle of the villages. Thus
making it very convenient for the farmers to contribute their milk. Further
more, the farmers are paid their money on the spot, based on quality and
quantity of milk. This also creates a meeting point for all the farmers to
discuss various new methods and techniques to increase their cattles
milk producing capacity. It also gives the farmers a sense of pride, as they
can be proud of the quality of milk being produced by their cattle.
HOW DOES KATRAJ DAIRY HELP THE FARMERS?
The collection centers pay the farmers for their milk on the spot
based on quality and quantity of milk. Because of which the farmers
dont have to wait on their money. Katraj teaches and educated the
farmers with new dairy technologies, thus keeping them up to date with a
global market. Katraj also provides the farmers with vitamins for their
cattle, to receive a better quality of milk. They also teach the farmers
what type of fodder is to be fed to the cattle when. They also provide
medical assistance for the cattle, to their limit.
Katraj is also trying to promote organic/green milk. Organic
milk is basically milk from cows that have been exclusively fed organic
feed, have not been treated with synthetic hormones, are not given certain
medications to treat sickness, and are held in pens with adequate space.
PRODUCTS PRODUCED AT KATRAJ DAIRY
MILK
Milk is an almost ideal food. It has high nutritive value. It
supplies bodybuilding proteins, bone forming minerals and health giving
vitamins and furnishes energy giving lactose and milk fat. Besides
supplying some essential fatty acids, it contains the above nutrients in an
easily digestible and assailable form. All these properties make milk an
important food for pregnant women, growing children, adolescents,
adults, invalids, convalescents and patients alike.
Milk may be defined as a whole, fresh, clean, lacteal secretion
obtained by the complete milking of one or more healthy Milch animals
excluding that obtained within 15 days before or 5 days after calving or
such periods as may be necessary to render the milk practically
colostrums free and containing the minimum prescribed percentage of
milk fat and milk-solids-not-fats.
Pasteurization: The term pasteurization refers to the process of
heating each & every particle of milk to at-least 63 C for 30 minutes, or
72 C for 15 seconds in approved and properly operated equipment. After
pasteurization the milk is gradually cooled to 5 C or below.
Homogenization: Homogenization refers to the process of
forcing the milk through a homogenizer with the object of sub dividing
the fat globules.
CREAM
When milk fat is concentrated into a fraction of the original
milk, that portion is known as cream. Cream is a rich portion of milk fat.
Cream is the product of cow or buffelo milk or a combination
thereof, which contains not less than 25 % milk fat.
Various Types of Cream
Table Cream } Containing 20
- 25 % milk fat
Light Cream
Coffee
Cream

Whipping
Cream
} Containing 30
- 40 % milk fat
Heavy
Cream

Plastic
Cream
Containing 65
- 85 % milk fat
Katraj Dairy has been manufacturing plastic cream with 65 - 75
% milk fat.
GHEE
Ghee is the pure clarified fat derived solely from milk or from
desi (cooking) butter or from cream to which no coloring matter is added.
Ghee is the clarified butter fat prepared chiefly from cow or
buffalo milk. Ghee is used as a cooking or frying medium, in
confectionary, for direct consumption with rice chappatis etc.
Cow ghee is mainly used in indigenous pharmaceutical
preparations (Ayurveda).
Packing Sizes:
500 gm. Poly pack.
500 ml standy pouch.
15-liter tin.
SHRIKHAND
Shrikhand is a semi-soft sweetish - sour whole milk product
prepared from lactic fermented curd. The curd (dahi) is partially strained
through a cloth to remove the whey and thus produce a solid mass called
chakka (the basic ingredient for shrikhand). This chakka is mixed with
the required amount of sugar, cardamom, jaiphal etc. to yield shrikhand.
Packing Sizes:
100 ml plastic cups
250 ml plastic cups
500 ml plastic cups
For Party or catering purpose available in loose bulk sale.
Best for occasions like Gudhi Padwa, Raksha bandhan, Dasara, Diwali
etc.
Direct consume with Puri, Chapatti, for better test.
AMRAKHAND
Amrakhand is a semi-soft sweetish - sour whole milk product
prepared from lactic fermented curd. The curd (dahi) is partially strained
through a cloth to remove the whey and thus produce a solid mass called
chakka (the basic ingredient for shrikhand). This chakka is mixed with
the required amount of mango flavour, sugar, cardamom, jaiphal etc. to
yield Amrakhand.
Packing Sizes:
100 ml plastic cups
250 ml plastic cups
500 ml plastic cups
For Party or catering purpose available in loose bulk sale.
Best for occasions like Gudhi Padwa, Raksha bandhan, Dasara, Diwali
etc.
Direct consume with Puri, Chapatti, for better test.
MALAI PANEER
Paneer refers to the milk solids obtained by the acid
coagulation of boiled whole milk & subsequent drainage of whey. The
acids commonly used are citric in both natural & chemical forms.
Traditionally paneer has been a variety of pressed channa, used
mainly in preparing cooked vegetable dishes like palak paneer, paneer
butter masala etc.
Packing Sizes:
200 gm rotogravure laminated pouch.
500 gm rotogravure laminated pouch.
1000 gm rotogravure laminated pouch
DAHI
Matka Dahi is a fermented milk beverage. Dahi originally was
set using mud pots since ancestral days for the purpose of getting that
unique flavour & taste gained due to the porous property of mud pots
allowing filtered air flow. But now a days dahi prepared from milk
faormenting with lactic culture & packed in plastic cups 370 C.
Packing Sizes:
100 gm. matka.
200 gm. matka.
100 gm. plastic cup.
200 gm. plastic cup.
400 gm. plastic cup
FLAVOURED MILK
Flavoured Milks are milks to which some flavours/ colours and
suger been added.When the milk is used the product should contain a
milk fat % at least equal to the minimum legal requirement for market
milk, but when fat level is lower(1.2%) , the term drink is used.
Packing Size:
200 ml Poly bag
LASSI
Lassi is a fermented Milk beverage popular in all parts of India.
The technology of lassi making is however confined to only households.
Lassi has a great potential in the Indian Market.
Packing Size:
200 ml Poly pack
JEERA / PLAIN TAAK (BUTTERMILK)
Tak is also called chhas or mattha, refers to desi buttermilk. It
is a popular drink during the hot Indian summers, as it helps reduce body
heat and lower the body temperature. Thus a relaxing drink enjoyed by
everyone.
Packing Size:
200 ml Poly pack
TABLE BUTTER
For years together, table butter is being cherished as a tasty
food, popularly eaten with bread. It also forms a good topping on
indegeous food like Pav-bhaji, Thalipith (Pan Cake). Katraj Table Butter
is marketed by Katraj Dairy Manufactured By Dynamix Dairy Industries
Ltd., Baramati, Maharashtra, India.
Packing Sizes:
100 gm.
500 gm.
SOFTY ICE- CREAM
This product is marketed in a soft condition and is ready for
consumption shortly after it is drawn from the freezer. Katraj dairy has
soft churner in their milk factory in the Pune city.
Among milk products ice cream is also rich source of calcium,
phosphorus and other minerals of vital importance in building good bones
and teeth.
It is a very desirable food item for growing children and person
who need to put on weight.
It is excellent source of Vitamin A, good source of Vitamin B
& G, Niacin, and Vitamin E. The digestibility & palatability of ice cream
is also very high.
Packing Size:
60 ml cone
PEDHA
Pedha is preparred using khoa based material. Khoa is mixed
with suger and then heated in a kadhai made of food-grade metal.After
heating desired flavouring and nuts are added to the pedha mass.
Packing Sizes:
1 kg box
500 gm. box
250 gm. box
ICE CREAM
Ice-Cream may be defined as frozen dairy product made by
suitable blending & processing of cream & other milk products, together
with sugar & flavor, with or without stabilizer or color & with the
incorporation of air during the freezing process. According to PFA rules
Ice-Cream is the frozen product obtained from cow or buffalo milk or a
combination there of or from cream and or other milk products with or
without addition of cane sugar, fruit, fruit juices, preserve fruits nuts,
chocolate, edible flavors & permitted food colors.
Nutritive Value; Among milk products, Ice cream is also a
rich source of calcium, phosphorus & other minerals of vital importance
in building good bones & teeth. Being rich in Lactose, Ice-Cream flavor
greater assimilation of calcium in the diet. The protein content of Ice
Cream is also rates high, both in quantity & quality. Ice Cream provides
valuable proteins in a very palatable form. In fact, Ice Cream is most
palatable source of milk protein to the vegetarians. Ice Cream is an
excellent source of food energy. It is a very desirable food item for
growing children & persons who need to put on weights. Ice-Cream is a
rich source of many essential vitamins, without which normal health &
growth cannot be maintained. Thus it is an excellent source of vitamin
-A, a good source of vitamin -B (Thiamine) & G (Riboflavin) & a fairly
good source of Niacin, vitamin - E & in fruit Ice Cream of vitamin -C.
The digestibility & palatability of Ice Cream is also vey high.
Flavors;
Packing Sizes:
50 ml plastic cups
100 ml plastic cups
500 ml Family pack
1000 ml Party pack
2000 ml Party pack
4000 ml Bulk pack
STERILIZED FLAVORED MILK
Sterilized milk may be defined as milk, which has been heated
to temperature of 1210C for 15 minutes. The Milk fit for human
consumption for at least 120 days at room temperature.
Flavors;
Packing Sizes:
200 ml Glass Bottles
KATRAJ AQUA (MINERAL WATER)
Katraj Dairy with their well-known products now introducing
mineral water with katraj brand i.e. Katraj Aqua. Water in its purest form
is really a life giving liquid. Katraj Aqua (to live a healthy family life)
gives the assurance that each drop of water that you consume is full of
energy & freshness. Our dairy is also an ISO- HACCP 9001-2008
certified Dairy and it stands testimony to the quality of product. We
strictly follow the quality measures regarding hygiene and quality of
products.
Packing Sizes:
500 ml Bottle - packed in 24 bottles in 1 box.
1 liter Bottle- packed in 12 bottles in 1 box.
MANUFACTURING PROCESS
Initially, the milk is collected in the collection centers in the
villages. This where all the villagers come and sell their milk to Katraj
Dairy. After which, the milk is transported to the Katraj plant, situated in
Katraj, Pune. The milk is transported in special vehicles designed for the
sole purpose of milk transportation.
[MILK TRANSPORTAION VEHICLE]
Once the milk has reached the plant, it is first checked for its
quality. After which it is primarily filtered and added to the holding tanks.
After which the milk is transferred through pipelines to the boiler unit.
This is where the milk is the milk is boiled to kill germs and make the
milk last longer, known as pasteurization.
[BOILER ROOM]
Pasteurization refers to the process of heating each & every
particle of milk to at-least 63 C for 30 minutes, or 72 C for 15 seconds
in approved and properly operated equipment. After pasteurization the
milk is gradually cooled to 5 C or below.
[REFRIDGERATION DEPARTMENT]
After this process the milk is stored in its specially designed
storage containers. After which it is ready for further processing and
packaging. The milk can be further be utilized in the production of rest of
the products like flavored milk, ice cream, butter, ghee etc.
[STORAGE TANKS]
QUALITY CONTROL
Katraj Dairy is very strict when it comes to the quality of the
milk and its products. It strictly maintains its standard as per ISO
9001:2000 regulations. The work of this department begins, as soon as
the milk enters the gates of the factory. They initially check the quality of
the milk when it is in the milk tanker or milk transportation vehicle. They
do so to ensure that the milk is not spoiled and does not match the
standards of Katraj Dairy. This process is carried out to ensure that; bad
milk does not get added to the rest of the milk in the storage units.
This department uses the method of random sampling for
selection of samples to test. It picks up random samples from all the
batches of products produced. If even one product in the batch is not up
to the mark, the entire batch of the product produced is discarded.
This department uses a variety of testing methods for the
various products that are produced at the plant. They usually check for
pH, fat, acidity, water content, saturation levels, lactic acid, etc. A hew of
the chemicals that they use for testing are given below-
Iodine Solution
Sodium Bicarbonate
Lactic Acid
Diastix
Silver Hydroxide
PACKAGING
Katraj Dairy carries out a very simple form of packaging. It is
appealing to the consumers eyes even if they are from a metropolitan
city or a local village in Maharashtra. All of their packaging has the local
dilet, Marathi on them along with the universal language, English.
[MILK PACKAGING]
The packaging is done in a very hygienic environment. All the
workers that come in contact with the products have hair caps and gloves
on their hands. They also have a special uniform that has to be worn.
The packaging of all the milk except the flavored milk is done
in polythene bags. The bags are manufactured in other parts of
Maharashtra and are inserted into the packaging machines. The flavored
milk is packaged 200 ml. glass bottles. Ice cream is packaged in plastic
cups as well as cardboard boxes.
DISTRIBUTION
Katraj Dairy has a simple of chain distribution. They follow
two chains of distribution,
1. Manufacturer `-"-
2. Manufacturer
`"-"-R""-"-`
-"-
[CONTAINERS IN, WHICH MILK IS DISTRIBUTED]
A list of distributors that are located in and around the city of
Pune, are given on the next page-
NAME OF DISTRIBUTOR AND AREA OF DISTRIBUTION
Gurukrupa Associates (Mrs.
Deepali V. Bhadale)
Sinhagad Road, Bibavewadi to
Swargate
Kaniphnath Milk Agency (Shri.
Balasaheb V. Gavhane)
Swargate to Shivajinagar, Ghorpadi,
Mundhava, Hadapasar
Shivam Milk Agency (Shri.
Sandeep U. Ghate)
Market Yard, Kondhava
Gaon,Undari, Satav Nagar
Mahadeonagar, Urali devachi
Balaji Milk Agency (Shri.
Sanjay R. Ambekar)
Vanwadi gaon, Salunke Vihar,
Manish Park
Assa Associates (Shri.
Amarpalsing Badh)
Pune Camp, Nana Peth, Bhavani
Peth, Koregaon Park
Om Sai Distributors (Shri.
Anil S. Londhe)
Yerwada, Kalyani nagar,
Vadgaonsheri, Viman nagar,
Vishrantwadi, Dhanori
Sidhdheshwar Milk Agency
(Shri. Sagar K. Shelake)
Renghill Corner, Bopodi, Khadaki,
Dapodi, C.M.E., Sangavi, New
sangai
Shevantai Milk Suppliers (Shri.
Ravindra D. Takke)
Gokhalenagar, Chaturshrungi
Payatha, Paud Phata, Jaibhavani
Nagar to Chandani Chowk
Sayali Milk Suppliers (Saui.
Vaishali K. Gopalghare)
Yerandavana, Karve Nagar, Varaje,
Uttam nagar, Kotharud gaon
Shriraj Milk Agency (Shri.
Rajendra J. Bhargude)
Rakshak Nagar, Sathe Pimple,
Kalewadi Phata, Wakad, Dange
chowk, Tathawade, Ravet, Punawale
Yamuna Traders(Shri. Ramesh B.
Phanse)
Kasarwadi, Pimpari,Kalewadi
Dattakrupa Enterprises (Shri.
Subodh N. Kale)
Vivek Vasahat, Shridhar Nagar,
Sudarshan Nagar, Udyog Nagar,
Bijali Nagar, Chinchwad Gaon
Vyankatsh Milk Agency (Shri.
Rohidas K. Lawande)
Akurdi Gaon, Akurdi-Nigadi
Pradhikaran,Dehuroad, Talegaon
Dabhade,Kamshet, Lonawala
Rudra Enterprises (Sau. Chhaya C
Jagtap)
Sant Tukaram Nagar, Ajamera,
Neharu Nagar, Balaji Nagar,
Indrayani Nagar, Landewadi,
Bhosari Gaon
Kunal Milk Agency (Shri. Rahul
D. Takke)
Pashan, Sutarwadi,Bavdhan, Boys
Batalian, Aundh gaon
Shri Saikrupa Distributors (Shri.
Amod B. Pandhari)
Someshwarwadi, Sanewadi,Parihar
chowk, Dattanagar, balewadi,
Hinjwadi
Radha Krishna Milk Agency
(Shri. Sandip D. Chambhare)
Morwadi, Ajamera, Mohan Nagar,
Yamuna Nagar, rupi Nagar,
Talawade, Phule Nagar, Chikhali
road, Shahu nagar
MAINTENANCE OF THE PLANT
A manufacturing unit like the one at the Katraj Dairy plant has
many machines, electrical units, etc., that needs regular maintenance.
Katraj Dairy has a fixed routine that covers all the maintenance-required
units.
[ELECTRICAL MAINTENANCE DEPARTMENT]
Machinery- All machinery requires maintenance. The maintenance
is determined on the number of hours that it has been operated. Based on
this the wear and tear of the various machine parts can be estimated. The
parts that usually require the maximum maintenance are the rollers of the
packaging units. The machines that come in contact with the milk are was
washed with boiling hot water, then with a chemical, then with boiling
hot water again and then washed with cold water. This process takes
place everyday with the small holding tanks.
Storage Tanks- There are two types of storage tanks when it comes
to maintenance, the big and the small. The big storage tanks are washed
on weekly bases while the smaller ones are washed on a daily basis. The
process involves, washing with boiling hot water, then by a chemical,
then with boiling hot water again and then washing with cold water.
Electrical Department- The electric department is in charge of all
the electrical lies that run through the entire plant. They usually have a
simple job of just changing the parts that whether down or fuse. A major
problem they face is rodents eating their underground wires, however,
they now run the cables through G.I. pipes. The other equipment that
usually burn out are the M.C.B.s, wires that fuse, motor pumps, etc.
[MAIN ELECTRICAL POWER HOUSE OF THE PLANT]
Refrigeration Unit- This unit is in charge of all the refrigeration of
all the products inside Katraj Dairy. It contains 6 compressors out of
which only 2 operate at a time. Each pair of compressors operates not
more than 6 hours at a time. When the demand for refrigeration increases,
4 compressors run at a time. Ammonia gas is used for refrigeration. If
there is low pressure in the lines of the ammonia gas, Sulphur powder is
added to the gas to help detect any leaks.
Pest Control- Rodents are a problem everywhere. To take care of
them crews of pest control are called every 1-month to spray pesticides to
keep the plant rodent free and hygienic.
BOARD OF DIRECTORS
The boards of directors have the power of all the decisions that
are to made, in regards to Katraj Dairy. The chairman of Katraj Dairy for
the term between 2009- 2013 is Mr. Shri. Rambhau Sambha Tule.
Mr. Shri.
Rambhau Sambha Tule.
Chairman
CONCLUSION
From this report we can conclude that the set up is not a
mediocre one, but in fact up to global standards. The plant is very
hygienic and well maintained. The idea and implementation of the idea of
unifying the farmers and helping them with their problems is nothing but
noble. All the products that are produced are of immense quality and
standard, because of which their consumer demand is growing day by
day.
Thus analyzing this report, we can say that Katraj Dairy is
definitely up to global standards and has the potential to be one of the
leading giants in the dairy industry.