Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
ON
STUDY OF MANUFACTURING AND QUALITY
CONTROL OF SUDHA DAIRY PRODUCTS
SUBMITTED TO THE
CENTER FOR AGRIBUSINESS MANAGEMENT
FACULTY OF AGRICULTURE
BIRSA AGRICULTURAL UNIVERSITY, RANCHI
SUBMITTED
BY
Year – 2010
1
BIRSA AGRICULTURAL UNIVERSITY
Faculty of Agriculture
Center for Agribusiness Management
Ranchi-834006
Date: …………………….
CERTIFICATE
This is certify that the work recorded in the project report entitled “Study Of
Manufacturing And Quality Control of Sudha Dairy Products” Submitted in partial
fulfillment of the requirements for the degree of MASTER OF BUSINESS
ADMINISTRATION IN AGRIBUSINESS of the Faculty of Post- Graduate Studies Birsa
Agricultural University, Ranchi (Jharkhand) is the record of the bonafide Project work
carried out by Praveen Kumar Mishra under my guidance & supervision. No part of the
report has been submitted for any other Degree or Diploma.
It is further certified that such helps or information received during the course
of this investigation & preparation of the report have been duly acknowledged.
ENDORSED
Major Advisor
(Dr. Niva Bara)
Director
Center for Agribusiness Management
2
BIRSA AGRICULTURAL UNIVERSITY
Ranchi – 834006 (Jharkhand)
(Certificate of the Advisory committee members &
Endorsement of Dean, Agriculture)
CERTIFICATE
I, the undersigned, as Major Advisor of the student for the Degree of
MASTER OF BUSINESS ADMINISTRATION IN AGRIBUSINESS have gone
through the manuscript of the report & agree that the project entitled “Study of
Manufacturing and Quality Control of Sudha Dairy Products” may be submitted by Praveen
Kumar Mishra in partial fulfillment of the requirements for the Degree.
ENDORSED
3
BIRSA AGRICULTURAL UNIVERSITY
RANCHI-834006
CERTIFICATE
This is to certify that the thesis entitled “Study Of Manufacturing And Quality Control Of
Sudha Dairy Products” submitted by Praveen Kumar Mishra in partial fulfillment of the
requirements for the Degree of Master of Business Administration in Agribusiness of the
Faculty of Agriculture, Birsa Agricultural University, Ranchi was examined and approved
on …………...
Director
Center for Agribusiness Management
Dean DRI-cum-Dean PG
Faculty of Agriculture Birsa Agricultural
University
Birsa Agricultural University, Ranchi Ranchi
4
ACKNOWLEDGEMENT
I wish to express my indebtedness, gratitude & special thanks to Dr.A.K Sarkar, Dean
Faculty of Agriculture, BAU Kanke, Ranchi for allowing me to carry out my industrial training
at Ranchi Dairy (Sudha plant).
It is my glowing feeling to record my best regards, deepest sense of gratitude to Dr. R.P
Singh, Director, Centre for Agribusiness Management for his judicious & precious guidance
which were extremely valuable for my studies both theoretically and practically.
I express my gratitude to Dr. Niva Bara, major advisor and my advisors Dr.B.K Jha, Dr.
R.P Singh, and Dr. V.Dhar for providing relevant information & co-operation during the
training.
I wish to express my indebted gratitude & special thank to Mr. A. K Sinha Manager, Mr.
D.K.Singh Dy. Manager, Mr. Arvind Kumar, and R.K.Tiwari, Sr.Tech. Supervisor of Ranchi
Dairy for their kind support into work and encouraged me in my endeavor and consented to
spend their valuable time to complete this job training.
I wish to express my heartfelt appreciation to my parent and friends for their constant
unending blessing, inspiration and sacrifice in the completion of this thesis.
Above all I bow down my head and offer my heartfelt devotion to the “Almighty God”
for his sacred blessing and enlightment in my life.
5
CONTENTS
1. INTRODUCTION 1-3
2. LOCALE OF THE STUDY 4
3. REVIEW OF LITERATURE 5-6
4. RESEARCH METHODOLOGY 7-13
5. FINDINGS 14-45
ORGANIZATION PROFILE
PROCESS OF SUDHA PRODUCTS
QUALITY CONTROL
6. SUMMARY AND CONCLUSION 46
7. SUGGESTION 47
8. BIBLIOGRAPHY 48
6
CHAPTER-I
1.1 INTRODUCTION
Dairy Industry is the most ancient industry in our country. Dairy is boon for the farmers
of our country farmer. Thousands of farmers and milk producers in and around the dairy have
benefited from the white revolution triggered by Sudha Dairy co-operative movement in
Jharkhand. The Integrated Dairy Development project or Operation Flood is being implemented
in three level co-operative societies. Producer‟s Dairy co-operative societies at village level,
Milk union at District level, and Milk Federation at State level.
HACCP (Hazard analysis and critical control point) and ISO 9001, 2000 certification
given by international standard organization engaged in food product manufacturing activities as
per international food safety need. Cooperative Dairies started this activity only to find
remunerative market for rural milk producer members. Mnemonic symbol is allotted by
NATIONAL DAIRY DEVELOPMENT BOARD (NDDB) the national level organization for
dairy related activities only after satisfactory implementation of quality assurance norms.
Deshratna Dr. Rajendra Prasad Dugdh Utpadak Sahkari Sangh Limited is the largest milk
union in the eastern part of India an industrially deprived region. DRMU has created modern
value - added processing and production facilities, it has a range of delicious Indian sweets under
the brand name of “SUDHA” in its fold. Viz Rassogulla, Gulab-Jabun, Peda, Kalakand, Misti
Dahi, Milk cake Sweet and condensed milk Product called Sudha Special, Paneer, Mango lassi
now “SUDHA” has been synonymous of quality in the area of milk and milk products and has
become household name in the eastern part of the country.
Today there are more than sixty five thousand farmers who are members of 980 village dairy
cooperative societies offer variety of value – added dairy products through the milk union in
competition in the open market and enjoying good margin out of dairy business. From a total
procurement of 0.90 million tones from our DCS (District Co operative Society) in the year of
1992, the production has gone up to more than 4.9 million tones in the last nine years or so.
Dairy products by 2011, dairy India projects the value of the industry to more than
double to Rs.520, 780 crore, which includes Rs.159, 600 crore from liquid milk, Rs.42, 680 crore
from ghee, Rs.50, 500 crore from khoa /chhena /paneer, Rs.9, 100 crore from milk powder Rs.2,
250 crore from table butter, Rs.6, 150 crore from cheese/edible casein and Rs.25, 050 crore from
other products. The India food industry is estimated to be worth over US$200 billion and
according to the confederation of India Industry (CII) is expected to grow to US$310 billion by
2015. India is one of the world‟s major food producers but accounts for less than1.5 percent of
international food trade.
7
India is the world‟s second largest producer of food next to China, and has the potential of being
the biggest with the food and agricultural sector. India is world‟s largest producer of cereals and
milk, Second largest producer of rice, wheat, sugar, fruit and vegetables, and inland fish and
third in cotton, Seventh largest producer of fish. Ranchi Dairy Ranchi (Sudha plant) was
established in March1991. It has proved itself as a lifeline of Ranchi in concern with milk and its
various products. Ranchi at present supplies, composition wise two different types of milk:-
And Sudha Dairy Products like - Mango lassie, Sudha Special, Paneer, Missti dahi, Peda,
Ghee, Butter table, Flavor milk, Fitness curd and Pasteurized milk etc. Fulfillment of consumer‟s
demand is not sufficient but the dairy products should be qualitative. In order to assess the
quality of Sudha Dairy product this study entitled “Study of Manufacturing and Quality control
of Sudha Dairy Products” has been planned with the following objectives:
Location – Ranchi Dairy Ranchi H.E.C., sector –II Dhurwa, Ranchi, Bihar State Co - operative
Milk Producers Federation Ltd. (COMFED) Patna.
Data collection- The study is limited to Ranchi Dairy. Data Processing is done by using
appropriate statistical tools.
Sampling Technique – Simple random technique was used for examining quality control of
milk and milk products of Ranchi Dairy:
1. Moisture test for these products i.e. - Paneer, Mango lassie, Sudha Special, Misti
Dahi, Peda, Fitness Curd & Pasteurized Milk.
2. Acidity test for Fitness Curd, Mango Lassie and Sudha Special.
3. Fat test for Paneer, Sudha Special, Misti Dahi, Peda, and Fitness Curd.
8
1.4 LIMITATION OF THE STUDY
The present study suffers from limitations of time and money and other constraints usually faced
by a student researcher. However considerable care and thought have been given in making the
study as systematic as possible.
9
CHAPTER- II
10
CHAPTER- III
REVIEW OF LITERATURE
The present chapter is devoted to review of related literature, for this an attempt in this
section has been made to review the available and relevant literature pertainting to the study.
Rathore (2006) in his study entitled “Dairy industry and it‟s by product” found the Dairy
Industries on one end producing value added Dairy Products and at the same time the by
products of Dairy Industries can also be used in number of ways for human beings. The Dairy
Business is quite profitable, if an integrated approach for utilization of main products and by
products is attempted. This not only supplies nutritional Dairy Products but at the same time
more earning to entrepreneurs.
Mathur and Mujumdar (2008) today, only about 15 percent of the milk produced in India are
processed. It has been shown that increased consumption of processed food led by, investment in
processing results in better remuneration to farmer. Presently only 12-14 percent of the milk
market is represented by packaged and branded pasteurized milk. Important sub sectors in food
processing, fish processing, milk processing meat & poultry processing, packaged/convenience
foods, alcoholic beverages soft drinks and grain processing etc.
Santos and Barbano (2006) in his study stated that the influence of raw milk SCC (Somatic
Cell Count) on pasteurized fluid milk quality is caused by increasing levels of heat-stable
proteases and lipases originating from the cow with increasing milk SCC. A row milk SCC of
100, 000 cell/Ml should be achievable at the farm level with appropriate financial incentives for
producers. High-quality, low - SCC row milk is a critical part of producing HTST milk with a
shelf life of 30 to 90 day.
Von bockelmann and Von bockelmann (1986) in his study “Aseptic packaging of liquid food
products” implies three different steps sterilization of the packaging material food contact
surface, creating and maintaining a sterile surrounding in the area where the sterilized product
and the sterilized packaging material/package are brought together, production of containers that
are tight enough to prevent entry of spoilage organisms. As far flexible and semi rigid packaging
materials are concerned, the following systems have entered the market of aseptic filling pouches
or bags, prefabricated cups, from fill seal cups from roll- stock material, plastic bottles,
prefabricated, paper- based laminated cartons, cartons produced from roll- stock material of
paper- based laminates.
11
Kansal (2006) in his study “Nutritional Qualities of Milk” examined that milk is a rich source of
all Vitamins, especially Vitamin A, Riboflavin and Vitamin B 12. Milk is a richest natural source
of calcium in the best available from. Milk contains. Several extra -nutritional constituents such
as conjugated linoleic acid spingomylins, butyric acid, myristic acid, and β-carotenes, which
protect against cancer, cardiovascular diseases enteric infection and diabetes, besides, having
immunomodulatory and slimming effect. Mother‟s milk contain large amount of several
antimicrobial substances such as immunoglobulin‟s, lactoferrin, lysozyme, lacto peroxides and
vitamin B12 binding protein that protect infants against enteric infection. Milk contains serum
cholesterol lowering factors. Lactic acid produced from milk sugar, lactose, inhibits the growth
of proteolytic and putrefying bacteria in the large intestine. There is no scientific base for
implicating milk cardiovascular disease, diabetes, cancers etc, and all such concerns are
unfounded.
Kumar and Baskarn (2006) prepared “strategies for development of dairy food parks” by
established such dairy food parks, we intend to improve the livelihood of the farmers through
cost effective pricing of milk, provision of employment opportunities and availability of milk
products at village level, there by the milk produced in large quantities at villages, will be
properly utilized without spoilage.
12
CHAPTER- IV
The sample in the aluminiumdish is kept in the hot air oven maintained at temp
100 +/-° C for 2 hours.
Mix properly
13
4.3 Moisture Test of Peda
A) Moisture content of peda
Aluminum disk with sample are kept in hat air oven & maintained by
temperature 100 ± 2° for 2 hour.
8.4
= ----------- × 100 = 84%
10
Result: - The T.S present in peda is 84% & moisture contain is 16%.
B.R × 11.25
% of fat = ---------------------------
Wt. of chopped peda taken in butyrometer
14
4.5 Moisture test of misthi dahi
T.S & Moisture content of Mishti Dahi
Aluminium dish with sample are kept in hot air oven & maintained the
temp.100 °C for 2 hour
3.5
= ---------------- × 100 = 31.5%
10
Result: - The T.S present in mishti doi is 31.5% & moisture present in Misthi dahi is 68.5%
B.R = 1.4
15
B.R × 11.25
% Fat in Mishti Dahi = -----------------------------
Wt. of Mishti Dahi transferred in butyrometer
1.4 × 11.25
= ------------------------- = 4.14%
3.8
Aluminium dish with sample taken are kept in hot air oven and maintained the
temperature 100 ± 1°C for 2 hours. After 2 hours cool the Aluminium dish and
sample in desieator.
Calculation:-
Wt. of dried sample
% of T.S = --------------------------- × 100
Wt. of sample taken
6.4
= ------------ × 100 = 64%
10
16
% of moisture = 100 - T.S = 100 – 64 = 36 %
Result: - The total solid percent in Sudha Special = 64% and T.S is 36%
BR = 1.7
Calculation: -
BR × 11.25
% of fats = -----------------------
Wt. of sample taken
1.7 × 11.25
= -------------- = 9.5
2
BR- 0.05
17
Calculation: -
BR × 11.25
% of fat = -----------------
Wt. of sample taken in butyrometer
Calculation:-
Acidity = Volume of N/1 NaOH consumed × 0.9
Aluminium dish with sample are kept in hot air oven & maintained the
temp.100 °C for 2 hour
18
4.13 Moisture test for mango lassie
1. Wt. of Aluminium dish = 14.2gm
2. Aluminium dish with sample taken are kept in hot air oven and maintained the temperature
100 ± 1°C for 2 hrs. After 2 hrs. Cool the Aluminium dish and sample in desieator
Calculation:-
1.8
= -------------- × 100 = 18%
10
Calculation:-
= 0.6 × 0.9
= 0.54 %
Result: - Acidity of Mango Lassie is = 0.54 %
19
CHAPTER-V
FINDING
A. ORGANIZATION BUSINESS PROFILE
It was observed that Ranchi Dairy has an area of 6 hectares. It is divided into 6
sections Plant processing section, i.e. Marketing section, Account section, Quality control
section, engineering section, and Store section.
Electricity dependency is on
• External sources
• Generator facility
20
6 Booster (defreeze 10 TR/h 2
compressor)
Altogether eleven types of technical features/facilities were observed during the study.
LOCAL
COLLECTION
COMPFED
RANCHI MILK UNION
Route: - Bero
Society: 1) Harhi
2) Masu
3) S.T.G.S
4) Mohegan
5) Treo
21
Route: - Pithoria
Society: 1) Hesalpiri
2) Turmuli
3) Bagda
4) Gesway
5) Urguttu
6) Meri
7) Manatu
8) Lowgada
Route: Meshra
Society: 1) Chutu
2) Meshra
3) Chetanbari
4) Khatanga
5) Badgari
Route: Mandar
Society: 1) Soba
2) Korabar
3) Barbary
4) Kharkutola
5) Daria
Route: Hocher
Society: 1) Hocher
2) Ekamba
3) Purnadih
4) Sangrampur
22
Route: Within city (Local)
Society: 1) Dahtola
2) Hatia
3) Gulamtoli
4) Kutee
2. Barauni dairy
3. Mithila Milk Union (Samastipur dairy)
4. Bhagalpur dairy
2. Hazaribagh dairy
2. Bhubaneswar dairy
23
5.5 Raw - milk tank
Raw milk tank -The quality control takes the sample of milk for testing and sampling. Milk is
graded in to three categories i.e. “A”, “B”, “C”, then after milk which is stored in raw – milk
tank goes for the next process.
24
5.7 Pasteurization
The process of pasteurization was named after Louis Pasteur who discovered that
spoilage organization could be inactivated in wine by applying heat at temperature bellow its
boiling point. The process was later applied to milk and remains the most important operation in
the processing of milk. Pasteurization is the process through which milk is treated at the
temperature of 80˚c ± 2˚c and it is done for destroying all pathogens and 99 % of non- pathogens
present on each and every ml. of milk.
Definition
The heating of every particle of milk or milk product to a specific temperature for a
specified period of time without allowing recontamination of that milk or milk product during
the heat treatment process.
Purpose - There are two distinct purposes for the process of milk pasteurization .
Public Health Aspect - To make milk and milk products safe for human consumption by
destroying all bacteria that may be harmful to health (pathogens)
Keeping Quality Aspect - To improve the keeping quality of milk and milk products.
Pasteurization can destroy some undesirable enzymes and many spoilage bacteria. Shelf life ca n
be 7, 10, 14, or up to 16 days.
The extent of micro- organism inactivation depends on the combination of temperature and
holding time. Minimum temperature and time requirements for milk pasteurization are based on
thermal death time study for the most heat resistant pathogen found in milk, Coxelliae Burnet.
Thermal lethality determinations require the applications of microbiology to appropriate
processing determinations. An overview can be found here:
To ensure destruction of all pathogenic microorganisms, time and temperature
combinations of the pasteurization process are highly regulated.
Pasteurization Regulations -
Milk: - 63°C for less than 30 minutes.
72° C for less than 15 seconds.
25
Fig. 4. Pasteurization
Methods of Pasteurization:-
There are two basic methods i.e. batch and continuous.
Batch methods: -
The batch method uses a vat pasteurizer which consists of a jacketed vat surrounded by either
circulating water, steam or heating coils of water or steam.
Continuous Method: -
Continuous process method has several advantages over the vat method. The most important
being time and energy saving, for most continuous processing, high temperature short time
(HTST) pasteurization is used. The heat treatment is accomplished using a plate heat exchanger.
This piece of equipment consists a stack of corrugated stainless steel plate clamped together in a
frame. There are several flow patterns that can be used. Gaskets are used to define the boundaries
of the channels and to prevent leakage. The heating medium can be vacuum steam or hot water.
26
5.8 Chiller
Chilling – Chilling is started after sampling that is only cold – treatment of milk which is done
with the help of running cold water.
Fig. 5. Chiller
5.9 Homogenization
Homogenization is the process to break down less digestible larger fat globules to smaller and
easily digestible one.
Fig. 6. Homogenization
27
5.10 Packaging - Machine
Packaging – Machine – From the Silo tank the milk comes to the packaging machine where the
milk is filled in packets of one liter and half liter respectively.
28
Process of preparation of various Ranchi Dairy products.
5.12 Milk
Milk is one of the important items of Ranchi Dairy.
Composition of milk
Milk is complex substance processing a number of physical and chemical properties. The
chemical compounds in milk include water, fat, nitrogenous compounds, sugar, vitamins,
mineral maters and other minor constituents in varying proportion. For details of constituents
and composition of different species, reference table s as follows:-
SL. No. Species Fat Proteins Lactose Ash Total Solids Water
Ranchi Dairy at present supplies, composition wise two different types of milk. The following
are fat% and SNF% (solid not fat) of the two types of Milk:-
Toned milk 3.0% and 8.5% solid non fat, Standard milk 4.5% fat and 8.5% solid non fat.
29
Toned milk contain/Liter
Price of Sudha milk and milk products are shown in table no.3
30
Constituents of Milk
MILK
Solid Non
Fat Water Fat
Minerals
Lactose proteins Phosphate Minor
True Associated & other citrates of Na, Constituent
Fats Substances Nitrogenous Ca, Mg, Cu,
products Fe, I, etc
Lecithin Dissolved Gases
Cholesterol
Pigments
Carotene
Casein Whey Proteins
Vitamins- B, B12&C
Vitamins A,
D, K&E
Enzymes
31
5.13. B PROCESS OF SUDHA PRODUCTS
Standardized milk (fat - 4.6 +/- 0.2%, snf - 8.6 +/- 0.2%) in storage tank
↓
Heating to 82 +/- 5°c for 15 - 20 minutes
↓
Mother culture cooling to room temp Sugar syrup
↓ ↓ ↓
Prepared culture → Inoculation of culture @ 1-2% heating to 82+/-5°C for
↓
↓
Breaking of curd at acidity 0.4 - 0.6% - L.A cooled down to 55° C
↓
Additions of sugar@20-25% of milk volume ← Filtration
↓
Additions of pasteurized chilled water
↓
Additions of mango flavor @ 0.6 ml/per lt. of milk
↓
Additions of mango pulp 16 %
↓
Addition of colour
↓
Homogenization
↓
Cooling
↓
Packaging
↓
Crating
↓
Storage
↓
Dispatch
Specifications:-
Total solids not less than 15%
Fat not less than 2.0%
Acidity not more than 0.85%
It has shelf life of 7days under refrigerated conditions
32
5.14 Production of pasteurized milk
33
5.15 Production of paneer
Standardized milk (fat- 4.6%, snf- 8.7%)
↓
Heating up to 80+/-2°C
↓
And cooling to75°C
↓
Coagulation with 1- 2% citric acid solution
↓
Collection of solid mass in hoops ← cleaned hoops
↓
Pressuring under 5 - 6 kg/sq.cm for 10 mins
↓
Pasteurized chilled water → cooling for 30 mins
↓
Storage
↓
Transfer to cutting table and slicing
↓
Packaging
↓
Transfer to cold store
↓
Storage (8° C or below)
Specifications:-
Fat not less than 50% of dry matter
Moisture not more than 70%
It has shelf life of 10 days under refrigeration.
34
5.16 Production of Peda
Specifications:-
Total solids should not be less than 80%
Fat should not less than 14%
It has shelf life of 17 days at room temp.
35
5.17 Production of Sudha Special
Standardized milk
↓
Boiling for 25 -30 minutes.
↓
Sprinkling of citric acid solution with brisk stirring
↓
Addition of sugar, corn flour, coconut powder
↓
Addition of colour
↓
Making Sudha Special mass
↓
Cooling Sudha special mass below 40°C
↓
Cup filling and sealing
↓
Transfer to cold store for storage below 10°C
↓
Dispatch
↓
Distribution
Specifications:-
Total solids should not less than 40%
Fat should not less than 6.0%
It has shelf life of 7 days under refrigerated conditions.
36
5.18 Production of dahi fitness curd and mishti dahi
Pasteurized Milk
↓
SMP/WMP→ Standardization and Homogenization of milk ← Sugar in Misti doi
↓
Heating milk
↓
Culture 1-2% → Cooling to39 +/-°C inoculate and mix
↓
Filling dahi cups
↓
Place in tray and transfer to incubators maintained at 39 +/-2°C
↓
Transfer trays to cold storage maintained at <10°C
↓
Fixing lids or sealing
↓
Cartooning
↓
Storage at < 10°C
↓
Dispatch
↓
Distribution
Specification:-
Fat %( min.) SNF % (min.) Sugar % (min.)
Fitness curd - 0.05 13.5 Nil
Mishti doi - 4.5 13.5 18.0
37
5.19 Marketing
Ranchi Dairy fulfills the demand of milk for a large part of Ranchi. Data of sales are
collected from the areas Ashok Nager, Pandra ,ITI, Piska More, Upper Bazaar, Firayalal, Ratu
road ,The data of sales collected are following:-
2. Pandra 1280
3. ITI 320
6. Firayalal 435
The management should take into consideration the 4p‟s of Marketing mix that are Product,
Price, Place, Promotion.
1. Product - Product is something that can be offered to the market to satisfy the need or
the want of the customers.
2. Price - It is the cost that customer is willing to bear for the product. Marketers need to be
very careful while deciding the price of the product.
3. Place - It involves decisions concerning with distribution channels to be used the location
of the outlets methods of transportation and the inventory used for the product promotion.
The milk market is dominated by a large number of small local milk farmers
known as “Khatal” milk. There are more than 200 local unorganized Khatals in Ranchi
Town. There are 5 other competitors of Sudha present in the market namely Shyam,
Nand, Megha, Dairy Fresh, and Mother Dairy. They act as a substitute of Sudha. Mother
Dairy is providing tough competition to Sudha in terms of quality.
38
Distribution Circle
Sudha Distributors Retailers
Consumers
Sudha distribution chain typically consists of the direct or one level channel. It has its own out
lets, which is provided by the District Development Board in the important places, sudha has
acquired those outlets to the retailers. Again the areas where the out let of the sudha is not
present, It distributes is milk for sale is through mini buses and jeeps which make the product
available to them on the prespecified time and takes the order from the retailers for the next
delivery.
Retail outlet -
They not only provide efficient sales channel but also provided safe storage. Sales for
the unit takes place the retailers take possession of the goods. The unit doesn‟t provide any
replacement policy so its increase cash circulation and also make calculation overall sales easy.
The outlet must be equipped with the freezing facility.
Convenience store -
It the retailer outlet is not available with in the 1km, range then the distribution is
performed by the convenience store .The retailing authority is given to those store, which have
the freezing facilities
2. Nand Rs.1.50
5. Shyam Rs.1.50
39
C. Quality control
Quality control includes a wide range of and scope of activities to be carried out
regularly. The ultimate task of quality control is to provide the plant management and persons
responsible for quality with information of fulfillment of previously defined quality critical and
standards at every stage of process as early as possible. Early warning about failures and inability
to meet quality standards at any stage of processing helps correct the situation in time and
decreases losses caused by irrelevant quality of the end product.
The planning and establishment of quality control for a milk plant includes the following: -
1. Organization and staffing of the quality control activity within the dairy plant.
2. Training the quality control personnel.
Definition of quality standards takes into account also the legal requirements for raw
materials, ingredients, packaging materials, processing line and equipment, end products,
storage, handling during distribution etc. Laboratory and methods for testing and analyzing for
the quality parameters includes organoleptic, physical, chemical and microbiological methods-
sampling methods and schedules.
40
5.21 Detection of adulterant in milk
Procedure Result
Take 1ml of milk. Then add 1ml Nitrate Blue Ring at the junction gives the positive test
Reagent along the side of tube. means that pond water added to milk.
2. Urea Detection
Procedure Result
Take 2ml of milk .Then add 2ml Urea Reagent Distinct yellow Colour formed. Urea has been
into it and mix well. added to milk.
Procedure Result
Take1ml of milk .Then add 2ml Ammonia Brownish colour formed. Ammonia Fertilizer
Reagent and mix well. has been added to milk.
Procedure Result
First boil 5ml of well mixed milk. Then cool it Blue colour formed. Starch and cereal flours
and add few drops of starch Reagent into it. has been added to milk.
5. Sugar Detection
Procedure Result
Take 1ml milk. Then add 1ml Sugar Reagent Red colour formed .Sugar/ Sucrose has been
and place it in boiling water for 3-5 minutes. added to milk.
6. Glucose Detection
Procedure Result
Take 1ml milk. Then add 1ml Dextrose Deep Blue colour formed .Glucose has been
Reagent 1 and place it in boiling water for 3 added to milk.
minutes. Then cool it and 1 ml Dextrose
Reagent 2.
41
Detection of adulterant in milk
7. Salt detection
Procedure Result
Take 5ml salt Reagent -1 and add few drops Yellow colour formed. Salt has been added to
salt Reagent 2 red colour will develops .Then milk.
add 1ml milk and mix it well.
8. Neutralizers Detection
Procedure Result
Take 5 ml of milk and add 5 ml Neutralizers Rose Red/ pink colour formed. Neutralizer has
Reagent 1 .Then add few drops of Neutralizer been added to milk.
Reagent 2 and mix well.
Procedure Result
Take 1 ml of milk .Then add few drops of Development of Pink/Red colour indicates the
Hydrogen Peroxide Reagent into it and mix presence of Hydrogen Peroxide in milk.
well.
Procedure Result
Take 10 ml of milk. Then add 5 ml Formalin Development of deep Purple/Violet ring at the
Reagent along the sides of the tube. junction indicates that Formalin added in milk.
2. The physical and chemical changes produced in milk due to bacterial growth. Such
information is useful for a variety of purpose e.g. Market milk control and grading,
improvement of farm and dairy sanitation practices for production of safe milk, screening
of milk supplies for their suitability for processing or manufacture of milk products and
detection of disease producing bacteria in milk.
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Sampling
The sampling procedure differs according to the purpose for which the sampling is
collected and the tests which are to be carried out. Samples should truly be representative of
bulk.
Since milk fat is of lower density than the other milk constituents, it tends to rise to the
surfaces. Thorough mixing of milk is essential to ensure a 26.5 - 29.5° C and agitation around
this temperature should be avoided. The sample is preserved with formalin or potassium
dichromate solution. From a single container: - It Involves mixing and then immediate sampling.
Mixing can be done either by using a plunger, which can be moved up and down in the milk
about 10 times. If it is small container it should be poured from one vessel to another. Care
should be taken to avoid fat separation.
From storage tanks and road milk tankers: - Mix the milk thoroughly using a large plunger or by
bubbling compressed air (aeration). Insert the plunger through the manhole move it downwards,
backwards and each time bring it the surface. Transfer 100 - 250 ml of the mixed milk with a
suitable dipper to the sample bottle.
5.23 The bacteriological tests carried out in Ranchi dairy quality control
1) Rapid plat from tests
A number of tests based on the rapid assessment of the changes brought about in milk as
a result of bacterial growth are performed. These tests are generally used for screening of
milk supplies on the receiving platform they are:-
A) Organoleptic Test: - judging the milk organolepticcaly by its flavor and odour
requires considerable skill which can be acquired only by practice. An experienced
person can pick out a bad sample of milk merely by tasting or smelling it with a fair
amount of accuracy.
B) Clot- on- boiling Test (COB): - This test is based on the observation that milk
samples having high - developed acidity due to bacterial growth are coagulated when
heated to boiling temperature. Milk acidity (lactic acid %) usually ranges from 0.126 to
0.144%. If acidity exceeds 0.153% the milk coagulates. Milk sample that coagulates
on heating are thus considered to have a high microbial load and hence are considered
to have reached the end point of keeping quality.
C) Alcohol Test
The stability of milk to alcohol is considerably affected by:
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The quality of milk is judged on the basis of formation of flakes and cots also the
colour of the mixture. Presence of flakes or clots indicates poor heat stability and
unsatisfactory quality of milk.
Apparatus
A thermostatically controlled water bath maintained at 37- 38° C. It is referred to
as a surgical box.
Sterile pipettes
Sample
Methylene blue
Procedure
1. The sample is aseptically added to the sterile screw capped test tube with
the help of sterile pipettes up to the 10 ml mark.
2. 1ml the dye is added aseptically.
3. The test tube is capped and the contents are cyclomixed.The tubes are kept
in the surgical box.
4. Controls are also kept for each sample. In the controls 1 ml of sterile
distilled water is added instead of the dye.
The tubes are inspected at intervals of 30 minutes. The sample is considered decolorized if the
blue colour disappears up to 5 mm from top.
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Interpretation
The longer the time for methylene blue reduction the better is the quality of the milk. ISD
Standards of MBRT test is shown in the following table-
Phosphates Test
Principle: - Micro - organisms produce an enzyme phosphate which decolorizes the dye
disodium paranitropheny phosphatase.Thus more the microbial load more will be the
decolourisation. This test is done to check the efficiency of pasteurization.
Reagents
1. 3.5 gm of Sodium carbonate, 1.5 gm of Sodium bi carbonate in 1 liter of distilled water-
solution A.
2. Disodium paranitropheny phosphate.
Procedure
1.) 100 ml of solution A is added to 0.15g of Disodium paranitrophenyl phosphate.
2.) 5 ml of the above solution mixed with 1ml of milk. Mix well and keep it in a water
bath at 37° C. Keep for 30 minutes.
Interpretation
If there is a color change after 30 minutes the milk is not pasteurized properly.
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5.25 Standard plate count method
Principle
Various dilution of the sample is prepared and pour plate technique is carried out. Plates
containing 30 to 300 colonies are counted. The colonies multiplied by dilution factor given the
number of colony forming units (CFU) per ml of bacterial population in the sample.
Apparatus
1. Sterile Petri plates and pipettes.
3. Sterile medium, the medium used in Ranchi Dairy is Dehydrated Nutrient media.
4. Agar 15.0
Plate count agar 17.5 Gms of powder is suspended in 1000 ml distilled water, heat to boiling to
dissolve the medium completely. Sterilize by autoclaving at 15 lbs pressure (121°c) for minutes.
Procedure
1. 1 ml of each dilution usually (1/10 & 1/1000) is transferred to the petriplates in
triplicates.
2. About 10 ml of molten media is added to each plate and plates are swired. On
solidification the plates are kept for incubation at 37°c for 24 hours.
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Interpretation
After incubation for 24 - 72 hours the plate are checked for the presence of pink colored
colonies. The presence of colifroms indicates faucal contamination. ISD Standards for SPC of
Raw milk is shown in the following table:
Apparatus
1. Sterile petriplates and pipettes.
4. Molten sterile medium. The medium is prepared from dehydrated powder. Ingredient of
Manconkey Agar (food) is shown in the following table-
3. Lactose 10.0
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4. Bile salts 1.50
7. Agar 15.0
p.H-7.1 ± 0.2
51.53 grams of powder in 1000 ml distilled water and boiled to dissolve the medium completely.
Sterilize by autoclaving at 15 lbs pressure (121°c) for 15 minutes mixed well before pouring.
Procedure
1. 1ml of each dilution usually (1/10 & 1/100) is transferred to the petriplates in triplicates.
2. About 10ml of molten media is added to each plate and plates are swirled. Solidification
the plates are kept for incubation at 37° C for 24 hours.
Interpretation
After incubation for 16 - 24 hours the plate are checked for the presence of pink colored
colonies. The presence of colifroms indicates faucal contamination. (No. of colonies Nil)
2. Dextrose 20.0
3. Agar 15.0
pH-5.6
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39 g of the powder is added to 1000 ml of distilled water, boiled to dissolve completely and
autoclaved. The plants are incubated at 20°C for 72 hours and the plates are examined for yeast
and mould.
Introduce molten Mac Conkey‟s Agar medium aseptically at 42 - 44°C into the dishes mix by
rotating and tilting dishes without spreading over the edges. Allow to solidify invert the plates
and incubate at temperature 37 ± 0.5°C for 24 hours.
6. When the contents are properly set, the petridishes are incubated for 5 days at
room temperature.
1. Below – 20 Good
2. 21- 50 Fair
3. 51 – 100 Poor
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5.28 Swab test for checking the sanitary condition of plant equipments
including pipelines
The sanitary conditions of the plant and equipments including storage tanks, vat, coolers,
pipelines, heat exchangers, agitators etc. is tested using the swab technique.
Principle
In this method a sterile cotton or wire gauge - swab (wetted with buffer solution) is
rubbed over the surface of the equipment and the bacterial cells removed from the surface are
transferred into the sterile buffer solution and their numbers estimated by S.P.C.
Requirements
1. Apparatus and materials for taking S.P.C.
Preparation of swab
The wire gauge consists of cotton wool wound around the end of a metal wire. Take a
piece of metal wire (35 cm long, 2.6 mm in diameter) formed into a loop at one end leaving a
straight length of 30 cm and notched at the other end to hold the gauge or cotton wool round the
notched end of the metal wire over a length of 50 mm. Place the swab in 25 ml phosphate buffer
solution in the test tube plug with cotton wool and sterilize.
Procedure
1. Press the swab with rolling motion against the wall of test tube to remove excess liquid
and take it out of the tube.
2. Rub the swab with heavy pressure back and forth over the to be examined so that all parts
of the surface area are treated twice. The swabbing should be repeated over 9 spots, of
10×.5 cm area in different parts of the surface so that the total area comes to 900 cm². To
facilitate swabbing over required area a thin rod with a cut out area of 10×5 cm in the
center is sterilized and used for guidance.
3. After rubbing the required area return the swab to the solution in the tubes in which it
was originally placed.
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5. Prepare 1/10 dilution of the sample.
6. Transfer 1 ml portion of the swab as well the 1/10 sample into duplicate plates and add
agar 48 hours.
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CHAPTER- VI
52
CHAPTER- VII
Suggestions
There is requirement of better communication & Co- ordination among the different
departments.
Human Resource Management should be more skill development and incentive payee.
The retailing authority should be given to those stores, which have the freezing facilities.
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CHAPTER- VIII
Bibliography
Barbano, D.M and M.V Santos (2006), Influence of raw milk quality on fluid milk shelf life,
J.Dairy Sci.89 (E.Supp.): E15-E19.
Bernhard A.H von Bockelmann and Irene L.I von Bockelmann (1986), Aseptic packaging of
liquid food products, J. Dairy food chem, page no.-384-390.
Mathur, B.N and A.S Mujumdar (2008), Value addition and product diversification, Indian Dairy
Man page no. 61- 82.
Rathore, N.S (2006), Dairy Industry and it‟s by product, “All India Dairy Business Directory”,
Third Edition, page no. -57-61.
Kansal, Vinod Kumar (2006), Nutritional qualities of milk, “All India Dairy Business Directory”
Third Edition, page no.106-114.
Kumar C.Naresh and D.Baskarn (2006), Strategies for development of dairy food parks, “All
India Dairy Business Directory” Third Edition, page no.77-79.
www.google.com
www.amul.coop
www.amulicecream.in
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