Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
I INTRODUCTION 2
IV COMPANY PROFILE 6
V PLANT DETAILS 6
VI WORKING TIME 6
IX FUNCTIONAL DEPARTMENTS 9
XI CONCLUSION 31
WORK DAIRY 32
1
I. INTRODUCTION
Education is usually pure and theoretical but training is always applied and practical.
Training gives more contents on short duration quickly and apparent result. The training aims to
improve personality of human. It is the learning process that involves the acquisition of
knowledge, sharpening of skills, concepts, rules or changing of attitudes and behaviours to
enhance the performance of students.
By attending institutional training one can know how to perform a particular job
practically which had been studied theoretically. Only theoretical knowledge would not make a
person experienced but he should also know to apply it practically. Then the person can get more
skills on industrial during his training period.
Education gets full shape after the proper training. Training operates and fulfils the
educational concepts by applications. Training influences by bringing new knowledge on our
attention.
We gained plenty of knowledge about how the concern was operated and its
functioning and also to know how they manufacture their goods and present it in the market with
best quality. Training helps us to gain practical knowledge about the employee behaviour and
production process in that concern. The basic training required for a trade, occupation or
profession is acquired through industrial training.
2
II. OBJECTIVES OF THE STUDY
To thoroughly study the various functions and process of each department and the
organization as a whole.
To develop professional skills through practical learning and to apply the acquired
knowledge for the study of relevant facts.
To provide concurrent opportunity for the integration of classroom learning in the field
and vice versa.
3
III. HISTORY OF THE COMPANY
A tiny village far removed from the bustling town it is today. But it was here, that
P.NACHIMUTHU GOUNDER laid the foundation of the SAKTHI GROUP. It was in this
year P.NACHIMUTHU GOUNDER broke away from his traditional business of hiring out
bullock carts, into pioneering a passenger transport service. From then on, there was no looking
back.
The ANAIMALAI BUS TRANSPORT (ABT), the parent organization of the Sakthi
group was founded in 1931 with over 21 buses and network in stages, to cover almost all of
south India.
In the year 1950, the company engaged itself in tea plantation under the name of
Bagavathi tea estates ltd and in the year the 1991 the company rechristened itself as ABT
Industries LTD, and then the company sold its tea estates and established manufacturing facilities
for fruit based beverages and took dealership for Telco vehicles and spare parts.
The dairy division was established in 1994, under the vision of N.MAHALINGAM for
procuring and processing 50,000 litres of liquid milk initially with plans for further expansion in
due course. The dairy division is presently procuring and processing 4, 00,000 litres of milk
every day. Its success in the dairy industry stems from its strong agricultural presence .It has 350
permanent workers. It is located in Marichanaikenpalayam at Pollachi. The liquid milk is
4
marketed in various towns of Tamilnadu and Kerala carrying the brand name of “Sakthi milk”. It
also manufactures and markets milk products like ghee ,curd ,butter ,paneer ,flavoured milk,
milk powder etc,. The success of the products comes from the division’s ability to maintain farm
–to –home freshness in each of the products. One of the reasons why Sakthi dairy products are
known for its quality is because the company controls each parameter quality from the udder to
the customer for the future. Sakthi milk stands in the 2nd place in Kerala renowned for its
quality. This division will be the thrust area for future growth of the company and the potential
for growth is immense. Products like sweetened yogurt, cheese, buttermilk, ice cream,
gulabjamun mix and milk powder for babies are being planned for introduction shortly.
Straddling one of the fastest growing business groups in India today, the Sakthi group is
an rs.1600 crore industrial conglomerate; its many successful member companies play a
significant role in the agricultural, industrial, financial, service sector and social development of
south India. The Sakthi group has spread its roots into sugar, industrial alcohol, Effluent
treatment plant, auto components, textiles, transport, finance, beverages, soya products, synthetic
gems manufacture and plantations.
In its pursuit of business excellence, the group has always thought of its social
commitment. As a dutiful corporate citizen, the Sakthi group has set up many educational and
charitable institutions, hospitals and religious centres .It has also made significant contributions
to rural development with a variety of social welfare activities and by creating employment
opportunities through its multi-fold agro-based and other industries. Sakthi Group, has also
forayed into the Ready to Cook (RTC) products category under the brand name ABT Foods,
offering seven new instant mixes.
Manufacturers of Sakthi Ghee, the company is offering Rava idli mix, Rava Dosa mix, Rava
upma mix, Pongal Mix, Payasam Mix, Gulab Jamun mix and Badam Milk mix. On future plans,
the has 25 more products in the pipeline, besides ice creams and sweets.
5
IV. COMPANY PROFILE
Name of the company: ABT Industries Limited (Dairy division product of Sakthi group)
Meenkarai road,
Pollachi-642103.
Nature of activity : Liquid milk processing and manufacturing of milk products like
V. PLANT DETAILS
Shift A : 6 am – 2 pm
6
Shift B : 2 pm – 10 pm
Shift C : 10 pm – 6 am
Shift G : 9 am – 6 pm
ABT dairy division brings to its customers a wide variety of quality dairy products including milk,
ghee, curd, paneer and flavoured milk. The division’s in-house dairy and infrastructure capabilities
ensure that each of these products promises quality and consistency of homemade goodness.
ABT dairy divisions “SAKTHI MILK” stands in the second place in Kerala in spite of no
advertisements, this is because of its promised quality. The first place is held by the Kerala’s government
company MILMA.
ABT dairy division is the First Tallest plant in the Coimbatore district. The Sakthi group has 13
wind mills at kanyakumari out of which 2 belongs to the ABT dairy division. The power derived from the
wind mills are sold to the Tamilnadu government and in turn they get a percentage of discounts on the
current price.
The company earlier had milk capacity of 4, 00,000 litres, presently it has increased its
capacity to 2, 00,000 litres. Similarly earlier ghee production capacity was of 2 tonnes, presently
in has increased it to 4 tonnes. Likewise the company wants to double and triple its production
capacity in the upcoming years. They are also on a mission to spread their branches all over
Tamilnadu and to become the market leader.
Sakthi milk is renowned for its quality and they want to maintain their consistency in
quality and timely delivery even as they grow in size, just as their tagline states....
7
THE PROMISE OF QUALITY”
8
VIII. ORGANIZATION CHART
CHAIRMAN
OPERATION
OFFICER
SUPERVISOR PROCUREMENT
SECURITY
CHILING
CENTER
9
ASSISTANT
OPERATOR
IX. FUNCTIONAL DEPARTMENTS
It thrives on the milk procured from the local farmers and from the villages across Tamilnadu. The
function of the dairy division starts from the procurement of milk from the farmers. Let’s look into the
routine work done by the farmers to secure milk from the cows.
10
The cow is milked.
The collected
milk is chilled to 4
11
degree Celsius using the milk chilling machine shown above. Raw milk is sent through a pipe into the
chiller machine, which has many compressed plates for chilling the milk and a meter is kept at the end of
the chilling process to check if the intended temperature has been met.
SILO
12
processes and to produce variety of products like ghee, milk powder, curd, paneer and flavoured
milk
IX.2. PRODUCTIO
N
BULK MILK CHILLER
DEPARTMENT
Once the milk is tested it is stored in silos, and it is then sent into the plant for various
processing’s.
PLANT
Milk process flow chart (1)
FARMERS
TANKER
RECEPTION(SILO)
HOMOGENIZATION
PASTEURIZATION
COLD ROOM
PACKING SILO
13
DESPATCH
PACKING MACHINES
MILK
The average composition of (raw milk) cow's milk is 87% water, 4.7 % milk fat and 8.5% Solids
Not Fat. This 4 degree chilled raw milk is sent into the cream separation process.
The cold raw milk passes through separator, which spins the milk through a series of conical
disks inside an enclosure. A separator removes debris, some bacteria, and any other sediment that may
be present .It also separates the heavier milk fat from the lighter milk to produce both cream and skim
milk. Once cream separation is done, the milk goes to the homogenization process.
14
Milk is homogenized to reduce the size of the remaining milk fat particles. This prevents the milk
fat from separating and floating to the surface as cream. It also ensures that the milk fat will be evenly
distributed through the milk; this ensures that every drop of the milk has the same composition and
taste. Once the homogenization process is done, the milk is piped into a pasteurizer.
Pasteurization is done to kill pathogens. The milk is heated at 72 degree Celsius to 76 degree
Celsius for 20 seconds, as it flows through the pasteurizer continuously. Once pasteurization process is
completed the milk is cooled to 4degree Celsius and it is sent to the batch silo.
STANDARDIZATION PROCESS
This is not a compulsory process. After the separation of raw milk into cream and skimmed
milk, the process of immediate, continuous reblending of a portion of the cream with the
skimmed milk to provide blended milk, while the remainder of the cream is recovered as a by-
product. This process is done for producing “special milk”.
PACKING
15
The milk is pumped into coated paper cartons (green, blue, orange, yellow) according to the milk
type and is sealed. Sakthi Milk comes in convenient 1 litre and 500ml packs. The milk packets are
stamped with a "sell by" date to ensure that the retailers do not allow the milk to stay on their shelves
longer than it can be safely stored.
The packed milk is stored at a temperature below 4degree Celsius. This room is freezing
and it has huge chunks of ice bars to preserve the milk.
DESPATCH
The milk packets are put into tubs with ice cubes and are then loaded into the van to be
taken to the market.
BUTTER
Fresh milk is first separated into skim milk and cream and the cream is then heated to 75%
Celsius -85%celcius for about a minute, this process is called pasteurization. Then the cream is chilled to
16
4degree Celsius for several hours. The chilled cream is piped into the churner which rotates to churn the
cream. The churner is filled to 40-50% of capacity to allow space for the cream to foam. Cream is
churned at 25-35 rpm for 5 minutes. The churner is stopped and the gases that are produced are
released. Cream is churned again at 25-35 rpm for 20-45 minutes. The cream gets thicker and it then
'breaks' to form ‘grains’ of butter and buttermilk. This process is continued until butter grains stick
together into large lumps. Keep the temperature as low as possible during churning. If the temperature
is too high, there are greater losses of fat into the buttermilk. Churning at low temperatures makes the
fat droplets in cream join together.
The butter milk is drained off, and the same amount of chilled or cold water is added to the
equal ratio of buttermilk removed. Churning is done at 10-15 rpm for 5 minutes and the water is drained
off. The churner is again rotated at 10-15 rpm for 10-20 minutes and the butter is now ready to me
removed. The butter is then used for producing ghee.
GHEE
PACKING
17
Lady workers are involved in putting on the lids and stickers having AGMARK seal on it. Ghee
is also available in 10rupee sachets. It has a long shelf life and it is stored in a cool, dry place before
despatch.
DESPATCH
The ghee is
available in 50ml,
100ml, 200ml, 500ml,
1litre and 15kg packs.
Finished ghee bottles are
packed into cardboard
boxes. They are
distributed in Kerala, Tamilnadu, and Andrapradesh. Ghee is also imported to Malaysia,
Singapore, Dubai and Kuwait.
18
CURD
Fresh milk is first separated into skim milk and cream. The skim milk is then pasteurized and
homogenised. This milk is again heated and a can full of quality curd is added to it and this mixture is
continuously churned .This mixture is then piped to the packing department.
PACKING
The curd is pumped into coated paper cartons. The curd is available in 200gms, 500gms and 1kg
packs. The curd packets are stamped with a "sell by" date to ensure that the retailers do not allow the
curd to stay on their shelves longer than it can be safely stored.
STORAGE ROOM
The curd packets are kept on incubation at a temperature of 42degree Celsius. This room has a
single fan which helps in maintaining the same temperature throughout the storage room.
DESPATCH
The curd packets are arranged into tubs and are loaded into the van to be sent to the market.
19
IX.3. STORES DEPARTMENT
It is a department where all the raw materials, semi finished and finished products are stored.
Apart from these, stationery and other goods are also stored. The stores play a major in stocking
requirements and meeting out the day to day requirements of various departments.
They maintain all the records of goods. When the stores run out of stock or the
requirements are more than the stock maintained, they make quick purchase from dealers or
retail outlets.
Stores are the sole respondents for making purchases; hence they also play the role of a
purchase department. There are a number of formalities to be met on making a purchase. Initially
the store’s manager ascertains the future requirements of all the departments and with the
signature of the particular department head, purchase order is placed. Once the order is placed,
invoice is given by the material supplier and once goods are received, goods receipt note is
given. And finally the purchase process is checked at the head office and then payments are
made.
The stores has materials like milk packets, bottles for storing ghee, labels, card board
boxes, and other materials as per the requirements. Stores also meet the requirements of the
maintenance department by making orders for machineries, spare parts, bikes and even
automobiles. Ultimately it has all the raw materials needed by all the departments and makes
purchase order when new requirements surface.
As stated above finished goods like bottled ghee are piled up in cartons and stoked in the
stores before despatch. Perishable goods like milk cannot be stored here as it needs refrigeration
so it is stored in the chilling room at 4 degree Celsius. All the records must be clearly maintained
and these records are sent to the head office on regular basis to check the accuracy. Hence stores
play a very vital role; it supports the important functions carried out by the production
departments and other peer departments.
20
IX.4. MARKETING DEPARTMENT
The liquid milk is marketed under the brand name of “Sakthi milk”. The milk sachets
are sold in two states Kerala and Tamilnadu. Around 1, 00,000 litres of milk are sold in Tamilnadu and 1,
00,000 litres in Kerala per day. It has 180 distributors including both the states.
Apart from the sales of milk, it also markets by products like ghee, curd and they are
being marketed through distributors .These products are also sold under the brand name
”Sakthi”.
The Sakthi ghee is authorised as AGMARK ghee by the central government and the ghee
is sold in four states like Kerala, Tamilnadu, Karnataka and Andrapradesh. The company also
exports ghee to Malasia, Singapore, Quwait and Dubai.
The curd is sold in sachets and in kilograms as per the requirements of its consumers; 1kg
of curd is priced at 35 rupees. The branch offices are located at Ernakulum, Trichur, Calicut,
Coimbatore, Madurai and Trichy.
HIERARCHY OF MARKETING
Producer-distributor-retailer-consumer
21
IX.5. HUMAN RESOURCE DEPARTMENT
This department deals with the man power requirements of the plant. At the plant level
the HR activities are undertaken by the personnel officer.
Going to the meetings convened at the head office on the following issues
o Issuance of minutes
o Factories act
22
o Minimum wages act
1. Man power: Keeping track of the occupied positions, vacancy, and the probable future
vacancy of permanent employees and contract workers. Listing out the retiring
employees in that year well before one year. The age of superannuation is 58years for
employees.
2. Discipline: Taking attendance, maintaining leave records, checking on late comings and
early leaving of the work spot. Taking action on habitual late coming and habitual
absenteeism. Watching over night shift workers and catching them red-handed for
sleeping.
23
4. Security: Looking into the records of visitors and checking if they are well maintained
by the security guards. Taking rounds in the nights to check on the night shift workers
and the attentiveness of the security guards. Checking on thefts and searching of prospect
employees who may have done it.
The important HR functions are (it is a deeper insight into the man power planning):
1. Pre-recruitment process
b) Scrutinise them and take approval from concerned authorities if the post is new.
2. Recruitment process
3. Joining formalities
24
c) Preparing and entering new hire paperwork
6. ISO compliance
c) Facing the internal and the external audits ,accountable to enforce the correctional
actions.
7. Statutory compliance
25
a) Handling PF and ESI formalities and coordinating with other departments.
b) Training need analysis is based on skill gap analysis, appraisal feedback and
suggestions.
9. Performance Appraisal
26
11. Report generation:
These are the important functions of an HR apart from the overall activities .Stated below are
some of the major responsibilities of HR Manager:-
3) To ensure timely recruitment of required level of staffs in order to meet business needs.
27
5) Develop, refine and fine-tune effective methods or tools of selection to ensure the right
people with the desired level of competence are brought into the organisation or are
promoted
6) Give focus on pay for performance and to ensure adherence to corporate guidelines on
salary adjustments and promotions
Thus if an HR Manager is efficient enough to handle and to take out best from his team members
any organisation can achieve more from his target goals.HR manager plays a very important role
in hierarchy, and also in between the higher management and low level employees.
HR Manager is one of the most important key to open a lock hanging on the door of success
in an organisation.
28
The various books and records maintained are cash books, ledgers concerning each and
every department, profit and loss A/C and balance sheet.
Pass book
Purchase book
Sales book
Creditor book
Debtor book
Sales tax
Income tax
Service tax
Water tax
Excise duty
Purchase tax
FINANCIAL PLANNING
Financial planning is taken at the board meeting by all the directors. Board meeting are
organized once in three months.
CAPITAL STRUCTURE
29
The Capital are brought in by the directors depending on their percent of shares in the
company.
CAPITAL BUDGETING
It is done by all the directors of the company during the board meeting. They will
estimate how much of working capital is needed for the production.
MAIN BANKERS
Bank of India
Canara Bank
30
3. Introduction of UHT plant (Ultra Heat Treatment)
FINDINGS
4. Introduction of Printing Manufacturing date, Batch Code, use by date in the milk packing
film by domino is good
SUGGESTIONS
31
XI. CONCLUSION
My Industrial Training at Sakthi Dairy division was very useful to understand the
activities of dairy plant thoroughly. We have also gained experience in problems handling during
labour shortage and other practical problems in producing good quality products.
Even though dairy field has a lot of competitors, Sakthi’s milk is becoming a big shot in the
market by emphasis on high quality products through well organized production planning and
marketing strategies.
In short, my training experience at Sakthi dairy division will help my future studies and career.
32