A

PROJECT REPORT
ON
IN-PLANT TRAINING IN ICE-CREAM AND MILK TESTING
TRAINING PERIOD:
13TH MAY 2019 to 14TH JUNE 2019

SUBMITTED BY:
NAME: KESHIKA MEENA
ENROLLMENT No. A0999318029
M.Sc. Microbiology
ACKNOWLEDGEMENTS:

I feel pleasure in expressing my profound sense of gratitude and indebtedness

to Mother Dairy organization which has given me the authority to get training
under them.
I am highly obliged to Mr. Ram Mohan Rao (Head of Mother Dairy) New Delhi,
Mr. Janmejaya Samal (HR. Manager) to arrange my training in their esteemed
organization.
I am thankful to Mr. V.G. Menon (HOD of ICP), Mr. Navneet Sharma (HOD of
QA/QC) for their support and guidance.
I am greatful to Dr. Ajit Verma (HOD of Amity Institute of Microbial Technology)
for giving me permission letter to work in this organization.
I thank all the workers in ICP and QA/QC lab that really showed cooperation
and support.

KESHIKA MEENA

This is to approve completion of industrial training at Mother Dairy and

submission of project report.

Mr. V.G. Menon Mr. Navneet Sharma

(HOD of ICP) (HOD of QA/QC)

Mr. Janmejaya Samal

(HR. Manager)
DECLARATION
I Keshika Meena, hereby declare that my report on topic
“In-plant training in ice-cream and milk testing” is a result of my own work
and indebtedness to work publications

Correction if any will duly acknowledge.

PLACE: Mother Dairy Food Processing Ltd, Patparganj, New Delhi.

Date:

KESHIKA MEENA
PREFACE
As the student of M.Sc. Microbiology, our aim should not be only to learn
theoretical concepts in the classroom, but it becomes more important as how
we apply those concepts in practices. In present scenario the world is
developing so fast and thus the technological and application theory is
changing at a greater phase. The study inculcates students to think out of the
box rather than emphasizing within the box. We are coming across many
modern theories and implementation of machineries, to start new business.
We must have knowledge of theories and practical, through it, the student can
be able to know how to apply their mind I the real business world.

This program of industrial training is to create awareness about the industrial

environment amongst the students.

The importance of industrial training and project preparation has been widely
accepted in the educational institutions. Thus knowing the importance of such
practical training, our college is providing with such a golden opportunity to
carry out my training in such a great organization. I have prepared the detailed
report regarding quality testing of production and testing of ice-cream.

I have tried my best to collect all the necessary information relating to my

project work.
ABSTRACT
The report consists of the details on Mother Dairy Fruit and Vegetable Pvt. Ltd.
It is one of the most effluent companies of India for processed milk and milk
products. The main aim of the welfare of the society is to provide quality milk
to its consumer at an affordable price. It has different practical divisions, for
example, the creation, Human Resources, Finance, Marketing, Purchase and
Stores, Quality Assurance, Dispatch and Logistics.

At Mother Diary process of milk is completed through progressive technology

that integrates and fully automates all functions of milk process and ensures
high product quality, dependableness and safety. After processing the milk is
dispatched in hygienic and sterilized milk tankers or packed in food grade
material and transported in cool chain. The various stages of milk processing
are:
1. Standardization
2. Clarification
3. Pasteurization
4. Fortification
5. Homogenization

In order to closely monitor the milk distribution across the city, milk tanks are
fitted with wireless and tracked with GPS. Dairy control organizes the tanker
routes to ensure the timely availability of milk in all the outlets.

During quality checking, the tanker goes to the market and the sample is taken
to check the quality. Many samples are also collected randomly by our field
staff from milk shop and retail outlets to maintain the stringent quality
standard’s of the Mother Dairy.
TABLE OF CONTENTS

TOPIC PAGE No.

1. Introduction 1-2
2. Mother Dairy bulk vending milk plant 3-5
3. Composition of milk 6-7
4. Role of milk in human life 8-9
5. List of quality tests 10-13
6. Processing parameters 14
7. CIP system 15
8. Ice cream process 16-20
9. Manufacture of ice cream 21-22
10. Food packaging 23-26
11. Production department 27-28
12. Dispatch and logistics 29
13. Facts and figures 30
14. Products gallery 31-32
15. Conclusion 33
16. References 34
INTRODUCTION OF MOTHERDAIRY
Mother Dairy is one of the largest liquid milk companies in Asia. It started its
organization in 1974 under the Operation Food Program of National Dairy
Development Board. Mother Dairy sources its prerequisite of fluid milk from
dairy co-agents and maker foundations.

Mother Dairy’s endeavor is to provide livelihood to farmers at the village level

by giving good price to their milk and quality products to the consumers at
reasonable price. So at Mother Dairy it’s a win-win situation for both farmers
and consumers. The keep the nation healthy and helps the farmers to live a life
of dignity. When you buy Mother Dairy milk you contribute to the nation’s
growth. Most of the farmers who are associated with the organization are
small scale farmers and females, so they take care of the marginalized section
and empowering the females in villages.

Today, Mother Dairy markets and sells milk and milk items including refined
items, desserts, paneer and ghee under Mother Dairy brand. The organization
likewise has enhanced portfolio with items in palatable oils, fruits and
vegetables, frozen vegetables, pulses, handled sustenance like natural
products, juices, jams, and so forth to meet the day by day prerequisites of
each family unit.

PROCUREMENT OF MILK
Mother Dairy produces its milk from the villages. Villages do have the
collections center where the farmers come with the milk. The milk is tested for
multiple parameters and the payment is decided on basis of the quality of milk.
Then the milk is taken immediately to the chilling center where it is chilled at
4°C to maintain the quality. After chilling, the milk is transported to the
respective plants in insulated tankers where it is again tested while receiving.
There are 25 parameters on which milk is tested and only when the parameters
are OK, the milk is considered as accepted. Then the milk is stored in large
insulated silos and it is processed in the plants.

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ADVANTAGES OF TOKEN MILK:
Mother Dairy bulk vended/ token milk is healthiest and tasty to the last drop.
The fat particle is broken down into small pieces and evenly distributed which
makes it easily digestible. The kids can consume the milk without filtering the
malai. It is vended by automatic vending machine. The milk is then fortified
with vitamin A and vitamin D which is good for making tea and curd. Such type
of milk does not require any polythene therefore it can be considered as
environment friendly milk.

POLY PACK MILK

Packaging of milk has undergone remarkable innovations in the past few
decades. Tamper proof, hygienic and labeled pouches/packs have replaced the
traditional bottle. These innovative methods of packaging milk have rendered
it free from adulteration and tampering and has also made possible to colour
code to their requirements.

1. FULL CREAM MILK ( Fat- 6.0% SNF- 9.0% )

Mother Dairy full cream milk is wholesome and healthy. Packed with energy
and nutrition that is essential for growing kids. It makes them stronger from
within and keeps them active and healthy.
2. COW MILK ( Fat- 4.0% SNF- 8.5% )
Cow milk contains simple proteins which are easy to digest. It is
recommended milk for children once they are weaned off mother’s milk
after 2 years. Cow milk leads to higher hydration which helps indigestion.
Additionally, homogenization breaks fat globules in smaller sizes thus
facilitating the digestion further.
3. TONED MILK ( Fat- 3.0% SNF- 8.5% )
Mother Dairy toned milk is the perfect blend of good health and wholesome
taste. It is an ideal choice for people in search of a nutritionally balanced
diet.
4. SKIMMED MILK ( Fat free and SNF- 8.7% )
Perfect choice for people who needs to reduce weight yet loves milk. This
milk has 30 times less fat than regular milk. It is rich in high calcium and
proteins.

2
MOTHER DAIRY BULK VENDING MILK PLANT
MILK PROCESS:

RAW MILK RECEPTION CLARIFICATION STANDARDIZATION

PROCESSED MILK PASTEURIZATION HOMOGENIZATION

DEEP CHILLING DISPATCH

RAW MILK AT RECEPTION

Raw milk obtained through protected rail tankers at a low temperature holds
the freshness of milk. The milk goes for about 25 stringent quality tests before it
is acknowledged for the processing of the same. Milk which is achieved from
individual makers is checked for all essential quality parameters meeting the
organization specification and required standards at respective gathering and
chilling focuses. Milk is then provided to the dairy units through protected milk
tankers at <4°C.

MILK PROCESSING (Pasteurizer plant)

Natural milk may contain little unwanted particles undetectable to the unaided
eye. All together to evacuate these particles the milk must be prepared. In any
sort of industry different procedures are attempted to process the crude
materials to acquire the final product. So each such procedure can be divided
into discrete steps which when attempted one by one lead to the complete
procedure.
At Mother Dairy, the procedure is to process the crude milk in the required
standard conditions and to achieve the last handled milk at the desired product.
The milk handling plant at the Patparganj unit is occupied with accepting any
sort of the crude milk from the state dairy organizations and procedure it to
deliver Toned Milk, after doing the pasteurization. The standards for the
prepared Toned Milk are as follows:
Fat contents: 3.05%
Solid non-Fat contents: 8.56%
Temperature: 2-4°C
Methyl blue re-coloration (MBR) time: 5 hours (minimum).

3
PROCESSING OF MILK
Clarification:
The chilled milk from silos goes to the clarifier after pre-warming. The clarifier
spins the milk rapidly, evacuating all the residue particles that are undetectable
to unaided eyes.
Standardization:
Milk from various breeds of cow may differ in its creations. Consequently, to
make milk uniform in creation, before supply to the market, it is Standardized
by raising or bringing down its Fat and SNF rate in the milk to an ideal
dimension, so as to convey the milk to customers according to standards of
FSSAI. The milk, which achieves the crude milk silos, is of various fat and SNF
composition. Usually raw milk silos 1, 2, 3 contains blended milk and 4 and 5
includes skim milk which may contain diverse extent of fat and SNF. To obtain
toned milk of 3% fat and 8.5% SNF diverse extent of milk from various silos is
determined and handled and are coordinated to prepared milk silos.
Homogenization:
In this procedure, the milk is handled at extremely high pressure during which
the huge fat globules present in milk and milk become more white and thicker.
Milk is homogenized for customer who don't like for cream layer on top.
Homogenization improves agreeability of milk and is effectively edible.
Impact of homogenization:
The fat globules of milk are surrounded by a film which is 5-10 mm thick. The
layer has properties of an emulsifier and keeps the emulsion, milk stable. During
homogenization the first layer is broken and the main outcome is a rise in
interfacial pressure falls again. The new emulsion stays stable even after
homogenization.
Pasteurization:
The milk is then pasteurized, named after Louis Pasteur, a French Scientist who
invented the procedure to use in milk. Pasteurization was first applied by Dr.
Soxhiet of Germany. This includes warming of milk to 72 degree Celsius for 15
second and afterward chilling it off to 4 degree Celsius. The procedure kills
every single pathogenic bacterium present in the milk making. It makes milk
ideal for utilization. Pasteurization, unlike boiling does not influence the
nutritional value of milk.

4
Chilling:
Here milk is finally chilled to 4-5°C utilizing chilled water which is being pumped
from ice storehouses. The chilled water temperature ranges from 1.5 - 3°C and
chilled milk temperature from 4 - 6°C. In the event that the chilled milk
temperature surpasses 9°C the milk will be again flowed through the systems so
a temperature transmitter persistently shows the temperature on screen with
the goal that nonstop observing should be possible and if temperature rise
constantly the refrigeration area make necessary action in order to decrease the
temperature. After chilling, milk is pumped to the storehouses.
Vitamin A and D addition:
Toned milk during preparation is sustained with vitamin A. Vitamin A addition is
done by adding acetic acid derivative. Vitamin acetic acid derivative is added to
the balanced tank after each shift. The amount included is 180 ml of vitamin A
acetic acid derivative in one lakh liters of milk with the goal that the milk
contains 2000 IU of vitamin A.
Function of Vitamin A:
You may know Vitamin A keeps up the well being and capacity of the eyes, yet
the supplement does considerably more than that, as well. Vitamin A plays an
important role in the health of the skin and delicate tissues and furthermore
maintains solid bones and teeth. You need a lot amount of Vitamin A to make
white platelets, which help you fend off infections. The Vitamin additionally acts
a cancer prevention agent, which means it shields your cells from harm that can
cause constant medical issues, for example, cardiovascular ailment and
malignancy.
Dispatch
After the fat SNF and quality testing of PM storehouse is done and amount is
full, the Silo is set apart for dispatch. Before dispatch milk is allowed to pump
over to glycol chillers and the milk is chilled to 2°C in glycol chillers. Here rather
than chilled water, chilled glycol of around – 0.5°C is passed into the chillers.
The chilled milk is then filled in tankers and the tankers at that point go to the
milk distributing units for deals.

5
COMPOSITION OF MILK
1. Milk Fat
Milk fat is the blends of 19 unsaturated fatty acids. The majority of fat in milk
exist as little globules with size approx. 0.1 to 22 microns. It is the type of an
oil-in-water emulsion.
2. Proteins
Protein is the most complex organic and natural substance. They are crucial
for living creatures as they establish a crucial piece of the individual body
cell. The protein of milk comprises of Casein, Lacto globulin and Lacto egg
whites. It is in colloidal state. Casein is just found in milk. It is effectively
coagulated by warmth treatment.
3. Water
It gives the medium wherein all the milk constituents are either broken up or
suspended. Its greater part is free and just a little bit is in bound structure,
being firmly by protein and phospholipids.

4. Lactose (Milk Sugar)

It is discovered distinctly in milk. It exists in pure solution stage and is
fermented by bacteria to yield lactic acid. It is significant for refined milk
item. It can likewise cause souring in milk and its items.

5. Mineral Matter:
In spite of the fact that it is available in little amount, it is basic for human
body. These are for the most part salts like Mg, Na, P, N and so forth. It
impacts physio-chemical properties of milk and furthermore influences the
nutritive esteem.

6. Phospholipids:
There are three kinds of phospholipids (Lecithin, Cephalic and
Sphingomylein). Lecithin is significant constituent as it helps in the
arrangement of external layer of fat globules.

7. Pigment:
There are two sorts of pigments present in milk, Fat Soluble and Fat
insoluble. Carotene is fat dissolvable and is in charge of the yellow shade of
milk. The other two are Xanthophylls and riboflavin. Carotene additionally
acts as an antioxidant and as a wellspring of Vitamin A.

6
8. Milk Enzymes
-Anise (diasterase) Starch
-Lipase Fat splitting, leads to rancid flavor
-Phosphatase It is capable of splitting certain phosphoric esters.
-Protease It is capable of splitting proteins.
-Catalase decomposed hydrogen peroxides.

9. Vitamins
Vitamins are available in small amounts in milk or some other substance
however plays a very significant job in essential working of human body.
There are 25 nutrients present in milk. These are fat dissolvable for example
Vit. A, D, E,K. aside from fat solvent there are water dissolvable nutrients as
B-complex(B1,riboflavin or B2, pantothenic acid, niacin, pyridoxine or B6.)

7
 ROLE OF MILK IN HUMAN LIFE
Milk is an essential and the most complete nourishment accessible in nature
for human utilization. Milk contains all supplements in adjusted proportions to
satisfy the need of people. It isn't fundamental for kids however it is each very
essential for grown-ups as well. Milk proteins are considered as high quality
proteins and are required for the proper growth of the body. Casein, the milk
protein, is just found in milk. Milk contains lactose (milk sugar) which is just
found in milk and on hydrolysis gives galactose and glucose. Lactose on aging
gives margarine, cheddar and dahi, which have high nutritive esteem and
consequently is significant for human life.
 1 Liter of Cow’s milk gives 720 Calorie (3000J) of energy.
 1 Liter of Buffalo’s milk gives 1100 Calorie (4600J) of energy.
 1 gm of milk fat gives 9 Calorie of energy.
 1 gm of Protein gives 4 Calorie of energy
 1 gm of Carbohydrate gives 4 Calorie of energy

Most milk is made out of 80 to 90 percent water. The rest of the 10 percent
comprise of an abundance of the significant supplements required by the body
for good well being, including fats, starches, proteins, minerals, and nutrients.

Cow milk regularly contains about 3.5 to 5 percent fat, which is scattered all
through the milk in globules. Also trademark, taste and surface to milk is
supplied by fat supplying nutrient A, D, E, and K, just as certain unsaturated fats
that the body can't produce. Lactose, a sort of sugar found distinctly in milk,
gives milk its sweet taste. Making up around 5 percent of milk's content,
lactose is a sugar that is broken down to provide energy. Babies digest lactose
effectively; however numerous grown-ups, particularly those of Asian and
African lineage, have lost a portion of their capacity to process this sugar. At
the point when these grown-ups drink milk, they frequently endure gastric
misery furthermore, looseness of the bowels.

The most significant protein in milk is casein, representing 80 percent of milk

protein. Casein is a complete protein, implying that it contains the majority of
the fundamental amino acids, which the body can't make without anyone else.
Casein particles and globules of fat redirect light beams going through milk,
giving milk its opalescent appearance. Different proteins present in milk
incorporate egg whites and globulin.

8
 Milk contains numerous minerals; the most of them are calcium and
phosphorus, also small amount of potassium, sodium, sulfur, aluminum,
copper, iodine, manganese, and zinc. Milk is maybe the best dietary source of
calcium—one liter (around 1 qt) of milk supplies as much calcium as 21 eggs,
12 kg (26 lb) of lean meat, or 2.2 kg (5 lb) of entire wheat bread. Milk is a great
source of vitamin A and B2. Vitamin D is commonly added to industrially sold
milk. Vitamin A, which is found in the globules of fat, is evacuated when fat is
skimmed away to make low-fat or skim milk. By and large, vitamin A is replaced
during the creation of economically sold low-fat milk.

Adulteration of Milk & Milk Product:

Adulteration:
Food adulteration is a demonstration of purposefully degrading the nature of
nourishment offered for sale either by the admixture or substitution of second
rate substance or by removal of some valuable and desirable substance. Food
adulteration considers not just the purposeful expansion or substitution or
deliberation of substance which unfavorably influence nature, substance and
nature of substance, yet additionally their accidental contamination during the
time of development, gathering, processing, handling, transport and
dispersion.
"Adulterant" signifies any material which is or could be utilized for making the
food hazardous or unsatisfactory or misbranded or containing unwanted
matter. Food is corrupted if its quality is brought down or influenced by the
expansion of substances which are damaging to health or by the expulsion of
substances which are nutritious. It is characterized as the demonstration of
purposefully corrupting the nature of nourishment offered available to be
purchased either by the admixture or substitution of second rate substance or
by the expulsion of some valuable substance.

Food is considered adulterated if:

 A substance is included which deteriorates or harmfully influences it.
 Cheaper or second rate substances are substituted entirely or to some extent.
 It is imitation.
 It is colored or generally treated, to improve its appearance or in the event that
it contains any additional substance harmful to health.
 For reasons unknown its quality is underneath its standard.
Contaminated food is risky on the grounds that it might be harmful and can
influence health.

9
 LIST OF QUALITY TESTS
1. Seal & Check for Cleanliness
2. Presence of Foreign Matter
3. Temperature
4. Organoleptic Evaluation
5. Clot of Boiling (C.O.B)
6. Alcohol Test
7. Neutralizer Test
8. Acidity Test
9. Ammonium Compound Test
10.M.B.R.T. Test
11.Urea Test
12.Starch & Cereal Test
13.Salt Test
14.Sugar Test
15.Glucose Test
16.Maltodextrin (Enzymatic) Test
17.Detergent Test
18.Formalin Test
19.Hydrogen Peroxide Test (H2O2)
20.Sodium Ions PPM Test
21.R.M. Value (Reicheret Missel)
22.B.R Value (Butyrometer Refract)
23.Fat Test
24.Protein Test
25.S.N.F. Test (Solid Not Fat)

Detection Method:
1. Seal & Check for Cleanliness
2. Presence of Foreign Matter:
 Take out 10 to 15 lit of milk in a bucket through a small hosepipe or
directly from the tanker valve.
 Filter this milk through muslin cloth or plastic sieve provided for the
purpose. Check for presence of foreign matter in the milk.
 If milk contains some undesirable matter, drain out some more milk and
check again.
 If foreign matter is found, reject the tanker. If no foreign matter is found,
climb on the tanker, check the hygienic condition.

10
3. Temperature:
 Temperature checked by using thermometer.
4. Organoleptic evaluation:
 Check taste & flavor of milk.
5. Clot of Boiling (C.O.B) Test:
 Conduct C.O.B test by taking 2 ml of milk in test tube
 Boil on the flame of spirit lamp. Due to formation of clots presence of
COB is indicated.
 Positive milk and is unacceptable.
6. Alcohol Test:
 Take 2 ml milk in test tube add 5 ml alcohol with constant shake,
formation of precipitates indicate alcohol test positive and such milk is
unacceptable.
7. Neutralizer Test:
 Take 2 ml rosalic acid in a test tube, add 2 ml of milk.
 Rose-red color development indicates neutralizer presence in milk and
disturbed salt balance is indicated due to presence of flakes.
 Such milk is unacceptable.
8. Acidity Test:
 Taking 10 milk and 10 ml distilled water in 100 ml conical flask
 Titrate against N/10 NaOH using phenopthelein as indicator to check
acidity.
 Acidity above 0.153% is not acceptable or use acidometer for titrable
acidity.
9. M.B.R.T. Test:
 Take 10 ml of milk in a sterilize MBR tube.
 Add 1 ml of MBR dye, plug with sterilize cork invert the tube mix the
content and incubate at 37°C in water bath.
 Check the test tube decolourization first after 10 min, next time after 30
min & subsequently every hour.
 Milk with MBR time less than 30 min unacceptable.
10. Urea Test:
 Take a test tube and add 2 ml milk in test tube
 Add 2 ml DMAB solution in the same test tube and mix the contents.
Appearance of yellow colour indicates the presence of urea and the milk
unacceptable.

11
11. Starch Test:
 Take 3 ml milk in test tube, boil and cool under tap water add 2 drops of 1
% iodine solution. Appearance of blue colour indicates the presence of
starch.
12. Salt Test:
 Take 2 ml of milk in test tube. Add 5 ml Silver Nitrate (AgNO3)
 Add 2 drops of potassium chromate indicates maroon colour is
acceptable otherwise unacceptable.
13. Sugar Test:
 Take 3 ml of milk in test tube and add 5 ml dilute HCL containing
resorcinol (0.1 gm resorcinol dissolved in 100 ml dilutes HCL).
 Mix well and keep the test tube in boiling water for 5 min. Brick red
colour formation indicates sugar is positive.

14. Maltodextrin (Enzymatic) Test:

 Take 10 ml milk in 100 ml beaker. Add 1 ml enzyme mix properly and
keep in water bath for 30 min. After 30 min check pH by using pH stripe.
15. Detergent Test:
 Take 1 ml milk in test tube. Add 1 ml of MBR dye mix well.
 Add 2 ml of chloroform followed by vortex for 15 sec.
 Centrifuge the content 1500 rpm for 5 min observe the layers after
centrifugation. Dark blue colour in lower ring then rejected, light blur
colour ring on lower ring so accepted.
16. Formalin Test:
 Take 2 ml milk sample in test tube.
 Add 2 ml of 90% sulphuric acid (H2SO4) containing ferric chloride (5gm in
100 ml H2SO4) from the side of the test tube slowly.
 Formation of purple ring at the junction indicates formaldehyde is
present in milk.
17. Hydrogen Peroxide Test:
 Take 5 ml milk in test tube and then add 5 drops paraphenylene diamine
and shake it well. Change the colour of milk to blue then it is positive.
18. Sodium ion PPM Test:
 For detection of sodium content of milk add 25 ml of sample in 50 ml
beaker with 2.5 ml of ISA and take reading. Final reading will be
displayed in PPM. Please do not switch off the instrument as it will
required calibration after power on.

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19. R.M. Value (Reicheret Missel) Test:
 Milk is collected then milk is converted into ghee.
 Take 5 gm of ghee in R.M. flask
 Add 20gm glycerol, add 2 ml sodium hydroxide (NaOH) after that saponify
on flame by using glass beet.
 After that add 90 ml boiling distill water and 50 ml Sulphuric acid (1 N)
then stand by for heating.
 After 20 min separate the RM flask and keep for cooling and filter by using
filter paper.
 After filtering take 100 ml solution 250 ml conical flask, add 1 ml
phenopthelein and titrate with N/10 NaOH change the colour of pink.
20. B.R Value (Butyrometer Refract) Test:
 Take one drop of ghee put on refractometer at temperature 40oC and take
reading.
21. Fat Test:
 Take 10 ml of milk in Butyrometer.
 Add 1 ml amyl alcohol
 Add distilled water for the level maintaining and tightly pack with stopper.
 Mix well and keep in Gerber centrifuge for 1500 rpm for 5 min.

22. Protein Test:

 Protein test is done by kjeldahl method.

23. S.N.F test:

 Warm the milk sample to 40oC to 45oC and maintain this temperature for
5 min.
 Mix the content by rotating and inverting the bottle taking care to avoid
the formation of air bubble and froth.
 Cool the sample to 15.5oC. Invert the bottle two or three times
 Pour enough milk into lactometer jar taking care to avoid the formation of
air bubble so that some milk overflow when they lactometer is inserted.
Insert the lactometer gently to weight the stem not more than a short
length about 3 mm beyond the position of equilibrium.
 Note the reading of the lactometer corresponding to the top of the
meniscus on the stem without the error of parallel.

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PROCESSING PARAMETERS:
Pasteurizer:-
Milk flow in the plant- 16000-18000 LPH
Pasteurization temperature- 78-800C
Chilled water temperature- 1-20C
Chilled milk temperature- 4-70C
Milk pressure in the plant- 2-3Kg/cm2
Regeneration Efficiency- More than 90%
Milk/water leakages- No leakage

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

Homogenizer:-
Lubrication oil level- 1/2 of level view glass
Lubrication oil pressure- 1bar (Minimum)
Milk pressure in HVA- 2000 PSI
Tension of belt- Normal
Oil leakage- No oil leakage
Milk leakage- No
Water leakage- No
Abnormal sound- No
Abnormal heating- No
Abnormal vibration- No

Milk Pumps:-
Shaft seal leakage- No leakage
Milk flow in the pump- 16000-18000ltrs/hr
Abnormal sound- No
Abnormal heating- No

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CIP SYSTEM:
Cleaning-in - place also known as In-place-cleaning refers to that arrangement
of cleaning and purification which does not require the day by day
disassembling of the dairy hardware.
Holders and machines working on milk are liable to the slow development of
microorganisms with the progression of time. So as to guarantee the best
possible handling of milk furthermore, no microscopic organisms goes to the
prepared milk the milk compartments for example the storehouses and the
plant must be cleaned following eight hours so as to guarantee legitimate
cleaning. Proper CIP plant is required in which cleaning set up is finished.
Further the CIP procedure is subject to the kind of the machine/holder and
there are just slight variations to the general methodology.

The cleaning process in general contains the following steps:

Solution Temperature
Lye (NaOH) 70 to 75OC
Acid( Nitric Acid) 70 to 75OC
Hot water 85 - 90OC
Soft water 37.40C

Process of CIP:
Step 1- Circulation of Cold water (soft)
Step 2- Circulation of lye solution, 30min.
Step 3- Circulation of hot water, 10min
Step 4- Circulation of acid solution, 20 min
Step 5- Circulation of hot water, 10 min
Step 6- Circulation of cold water.

15
ICE-CREAM PROCESS:
Selection of Ingredient
↓
Making the Mix
↓
Pasteurization of Mix (68oc for 30 min)
↓
Homogenizing the Mix (Stage I & II at 2500 & 500 psi)
↓
Cooling & Aging the Mix (0-4oc)
↓
Freezing the Mix (-4oc to -7oc)
↓
Filling of Ice-Cream
↓
Packaging of Ice-Cream
↓
Hardening & Storage of Ice-Cream (at -23oc to -29oc)

Processing Equipments:
1. Mix vat tank
2. Duplex Filter
3. Homogenizer
4. Pasteurizer
5. Chiller
6. Ageing tank
7. Freezer
8. Metal Detector
9. Fruit Feeder
10.Flavour tank
11.Cup Machine
12.Matka Kulfi Machine
13.Blast Room
14.OPRP (1- CIP, 2- Filter, 3- Air)
15.CCP (1- Pasteurization, 2- Metal Detector, 3- Cold Store)

16
QUALITY TESTS FOR ICE-CREAM
 Total Solid
 Fat Test
 Acidity Test
 Protein Test
 Phosphatase Test

1. Total Solid

Empty Dish weight

(It should be Cool and Moisture free)
↓
2 gm ice-cream Weight
(With Pipette)
↓
Spread in dish
↓
Put on Plate at 120oC
↓
Keep in Hot Air Oven at 102oC
↓
Weight

2. Fat test

Take a cylinder put on weighing balance

↓
Take 10 ml H2SO4 in Butyrometer
↓
5 gm of ice-cream weighed
↓
1 ml Amyl Alcohol
↓
Distilled Water
(For maintaining level) and shake after stopper
↓
Centrifuge for 5 min
↓
Reading observed

17
3. Acidity Test

Take conical Flask

↓
10 gm Sample
↓
Add 40 ml distilled water
↓
Add 1 ml phenopthelein
↓
Titrate N/10 NaOH
(Light Pink)
↓
Reading

4. Protein Test

Take conical Flask

↓
10 ml ice-cream sample
↓
Add 40 ml distilled water
↓
Add phenopthelein indicator
↓
Add 0.4 ml Potassium Oxalate
↓
Hold for 3 Min
↓
Mixing by Stirrer
↓
Add 2 ml Neutralizer Formaldehyde
↓
Again Titrate with N/10 NaOH
(Light Pink)
↓
Reading

18
5. Phosphatase Test

1 ml sample in test tube

↓
Boil the sample
↓
Add 5 ml dye
↓
Incubate at 37oC for 2 hr
↓
In every half hr see the condition
↓
Slightly yellowish (+ve)
↓
No Change (-ve)

Role of different constituents in ice-cream

Ice-cream has the following composition:
 It has greater than 10% milk fat or between 10-15% in some premium ice
creams.
 9-12% milk-solid-non fat (MSNF): this component also known as the serum
solids contains the proteins (caseins and whey proteins) and carbohydrates
(lactose) found in milk.
 12-16% of the sweeteners; usually the combination of sucrose and glucose
based corn syrup sweeteners.
 0.2 to 0.5% stabilizer and emulsifiers.
 55 and 65% water which comes from the milk or other ingredients.

Milk fat (or butter)

Milk fat or fat normally is very important to the ice-cream for the given
reasons:
 Increase the richness of flavor in ice cream
 Produces a characteristic texture by lubricating the surface.
 Aids in lubricating the deep freeze barrel throughout the manufacturing
process.
Limitations
 Cost
 Hindered whipping ability
 High caloric value

19
Milk Solid Not Fat (MSNF)
Milk Solid Not Fat (MSNF) contains the milk sugar, caseins, whey proteins and
minerals (ash content). Given ingredients are crucial for the following
reasons:
 Due to their protein functionality, they helps to improve the texture of ice
cream
 Helps to give proper chew resistance to the product
 It is a cheap source of solids and whey powder.

Sweeteners
A sweet dessert is generally wanted by the costumer. Accordingly,
sweeteners are added to dessert which is blended at a rate of typically 12 -
16% by weight. Sugars improve the surface and palatability of the frozen ice
cream, upgrade flavors, and are normally the least expensive source of
complete solids.
Likewise, the sugars, including the lactose from the milk parts, adds to a
depressed freezing point of solidification so the dessert has some unfrozen
water related with it at exceptionally low temperatures average of their
serving temperatures, - 15° to - 18°C. Without this unfrozen water, the frozen
ice cream would be too difficult to even think about scooping.

Stabilizers
Commonly used stabilizers are guar gum, carob bean gum and cellulose gum.
Their main function is that they reduce the growth the growth of ice crystal
by affecting the viscosity and many other rheological properties of ice cream
therefore the mobility of water in the frozen aqueous solution is limited

Emulsifiers
What is an emulsion?
An emulsion is a blend that outcomes when one fluid is added to another and
blended however, do not break up into it. A case of an emulsion is a
vinaigrette dressing where the oil is added to the vinegar and blended. In
spite of the fact that the oil is finely scattered, it doesn't break down into the
vinegar.
Emulsifiers keep the frozen ice cream smooth and help the circulation of the
fat atoms all through the colloid. Presently, two emulsifiers usually appear on
the fixings mark of many frozen ice cream formulations, to be specific, mono-
and di-glycerides, and Polysorbate 80.

20
MANUFACTURING OF ICE CREAM

Selection of ingredients

Mixing of ingredients
(Toned milk, SMP/WMP at 35°C, WPC, sugar + stabilizers at 60°C)

Figuring the milk

(Table butter and remaining sugar at 65°C)

Holding the mix for around 30 minutes

Mix transfer pump

Passing through magnetic filter

(1000 gauss)

Passing through duplex filter

(1000 mesh size)

Homogenization of mix
(60-65°C)

Pasteurization
(Inlet temperature- 65-70°C)
(Outlet temperature- 83-87°C)

Holding tube
(25 seconds)

21
 FDV
(If pasteurization is at lower temperature then mix is sent back to mixing vat)

Chiller
(Inlet temperature- 83-87°C)
(Outlet temperature- <9°C)

Ageing
(4-5°C for 4 to 6 hours)
For 2-3 days

Flavor tank

Continuous freezer
(-4 to -5°C)

Packaging

Passing through metal detector

Cold storage
(> -20°C)

22
INTRODUCTION TO FOOD PACKAGING
In the present society, bundling is basic and essential. It encompasses upgrades
and secures the products we purchase, from preparing and assembling,
through taking care of and storage, to the final buyer. Without packaging,
materials taking handling of would be a chaotic, wasteful and expensive
exercise and modem consumer promoting would be impossible. The packaging
part speaks to about 2% of Gross National Product (GNP) in created countries
and about half of all packaging is used to package food.

Meaning of packaging:
Packaging has been characterized as a socio-scientific discipline which works in
the public arena to guarantee conveyance of merchandise to a ultimate
customer of those products in the best condition proposed for their utilization.
The Packaging Institute International (PII) characterizes packaging as the
enclosure of items, things or bundles in a wrapped pouch, bag, box, cup, tray,
can, tube, bottle to perform at least one of the following functions-
 Control
 Protection
 Preservation
 Communication
 Utility
 Performance
On the off chance that the gadget or compartment performs at least one of
these capacities, it is considered a package.
Different meanings of packaging include a co-ordinate arrangement of getting
ready products for transport, appropriation, stockpiling, retailing and end-use,
a means of guaranteeing safe conveyance to a definitive buyer in sound
condition at ideal expense, and a techno-business capacity aim for advancing
the expenses of conveyance while amplifying deals.

Hazards of distribution
Important points to establish are:
 The types of transports are road, rail, sea or air.
 The degree of control over the transport – is it private or public transport?
 The form of transport – break-bulk, freight container, postal, passenger
train.
 The nature and intensity of the mechanical and climatic hazards in transport,
storage, retailing and use.
 Whether handling aids are available for loading and off-loading at all points
between maker and user.

23
24
Packaging of milk products:
1. Pasteurized flavored milk:
It ought to be filled in glass bottles and capping is done. LDPE lined
containers/aseptic containers or some other appropriate holders are
likewise been suggested.
2. Sanitized flavored milk:
It ought to be filled in glass jugs or clean jars, appropriately cleaned.
Polypapers or poly-laminated paper packs in tetrahedron, pyramid or on the
other hand different structures may likewise be utilized. The compartments
ought to be topped or fixed sealed shut and put in a sterilizer where they
ought to be slowly warmed to an appropriate temperature and cooled to
room temperature.
3. Sterilized milk:
It ought to be pressed in glass containers or sterile jars appropriately
sanitized and supplied so as to shield it from pollution. Polypapers or then
again polylaminated paper packs in tetrahedron, pyramid or different
structures may likewise be utilized.
4. Condensed milk/Sterilized cream:
These items ought to be pressed in hermetically fixed holders or LDPE lined
containers/aseptic containers. In case of condensed milk, the side crease of
the compartment might be patched or solidified. The kind of concrete
utilized should not confer any odd flavor to the milk and ought to likewise be
non dangerous.
5. Fermented milk products and Dahi:
They should to be filled in glass bottles or any other appropriate holder and
capped. They should not be presented to hotter temperature as the items
become excessively sharp because of development of microorganisms. The
matured milk items ought to be cooled before dispatch and kept up ideally
at a temperature underneath 10°C, to grow great flavor and surface.
6. Milk powder, Cereal weaning foods:
For the above items, the code has prescribed that these items ought to be
pressed in hermetically fixed and clean compartments so as to shield them
from decay. These may likewise be stuffed in hermetically fixed tinplate
holders in N2 or a blend of N2and CO2 gas. Other pressing material that
might be considered is bag in-box having inward layers made of PET/LDPE
which can be gas flushed. Baby milk food and entire milk powder when
made by the splash drying procedure ought to be pressed in N2 or a blend of
N2 and CO2 gas.

25
Plastic packaging material for Ice-Cream:
Plastics are natural polymers which are long chain atoms obtained by
expansion or buildup of one or more monomers. Polymerization of single
repeating unit gives homo polymers and expansion of more than one
monomer results in co-polymer. Plastics have turned into a noteworthy
packaging material, along with paper, metal and glass. Plastics are utilized
essentially for consumer packages in the form of wraps, pockets, containers,
sacks, tubes, jugs, jolts and boxes. In transport, they are utilized as sacks,
extend films for wrapping plate loads, containing unit packs or for entire
pallet loads. The advent of snack foods, accommodation food and prepared
food has been possible because of the accessibility of plastic bundling
materials.

Advantages:
 Barrier to water vapor and gases
 Light weight
 Good strength
 Design flexibility
 Resistance to breakage
 Machine’s ability- high speed filling using form fills and seal techniques
 Glossy and transparent
 Coloring is possible
 High tensile strength
 High tear strength
 High printability
 High level lamination
 Low cost

Disadvantage:
 The disadvantage of plastic is the disposability i.e. it is difficult to get it
disintegrated into soil.

26
ABOUT PRODUCTION DEPARTMENT
Production Department is most significant part in any association, firm, and
organization or on the other hand co-operative sectors. Production can be
made for the center client or for the end- client (direct customer). Productions
do the primary work changing the crude material into semi-complete or
completed merchandise. It relies upon what sort of production the
organization is doing.
With regards to Mother Dairy, individuals have endless demand for milk and
milk items. Mother Dairy undertakes the procurement of milk and its
production similarly fulfilling the necessities and request of individuals. It
evaluates the interest and accordingly production is accomplished for which
course of action of crude material, fund and arrangement for selling is made by
MOTHER DAIRY.
The production department is interrelated with the Personnel, Finance, and
Marketing Department. On an average 30 million liters of milk is processed by
Mother Dairy.

Production utilities:
We have discussed that the production of milk involves many processes and to
fulfill these processes there is the requirement of the hot water, cold water, air
for the operation of pneumatic valves and continuous supply of water, so the
question arises what are the sources of them?
The following utilities in the production department fulfill this:
1) Refrigeration - Cold water source.
2) Air compressors & Drier – Air for the operation of pneumatic valve.
3) Boilers – Steam and hot water source.
4) Nano water plant – fulfills the water requirement in pasteurizer plant.

Exercises of generation Department

There are mainly Eight (8) exercises done by the production division. They are
as follows:
1. Crude Material Receiving Dock 1. 5. Chilling
2. Clarification 6. Process milk
3. Homogenization 7. Profound Chilling
4. Pasteurization 8. Dispatch in Insulated Tanker

Mother dairy has set up the cutting edge plant for the creation procedure. It
has set up its plant in a cutting edge innovative style which capacities almost
80% automatically.

27
BASIC WORKING OF PRODUCTION UTILITIES

AIR COMPRESSOR REFRIGERATION

(FOR PNEUMATIC VALVE) (PROVIDES COLD WATER)

NANO WATER TREATMENT BOILER

(FOR PURE WATER) (PROVIDES HOT WATER)

MILK
PLANT

EFFLUENT TREATMENT
PLANT (ETP)
FOR WASTE WATER

28
Dispatch and Logistics

All activities carried out under the supervision and general manager of
marketing head i.e. order of milk and milk products are dispatched as per the
order of the retailer and customers and all record of dispatch are kept in
dispatch register and computer.
In this department work is divided into 3 shifts:
Morning
Afternoon
Evening

Sources of mode of transportation

There are insulated vans, trucks, tempos and three wheelers used to deliver
milk products in all the three shifts.

29
FACTS AND FIGURES

30
CONCLUSION
Mother dairy is one of the largest liquid milk plants in Asia. It sells more than
32 lakh liters of milk per day, out of which approximately 11.5 lakh liters of
milk is sold as bulk vended milk and another 19lakh liters of milk is sold in
sachets in 5 different variants i.e. full cream, standardized, toned, double
toned, skim milk across 6 states.

In an effort to conserve fuel, mother dairy utilizes the abundant solar energy
to preheat the water going into the boilers.
For maintaining ground water level, a rain water harvesting plant has been
installed in the dairy premise.
There is an effluent treatment plant in which the water used for cleaning the
equipments and tankers is treated before being discharged into the sewage
system.

Strategically located mother dairy managed more than 1000 milk shops
across Delhi and NCR make it convenient for the consumers to pick up their
daily requirement of milk, flavored milk, butter, Dahi, Lassi, mouth watering
ice creams etc. mother dairy’s state of the art processing and stringent
quality management system ensure that the consumers get the best quality
products from its large range of products portfolio.

I understood all the working of the plant and the department and the
interconnection associated between them. I felt very honored and privileged
on doing my training from such a reputed firm of country India.

33
REFERENCES
1. www.nddb.org
2. www.ndri.res.in
3. www.censusindia.gov.in
4. www.dairy.maharashtra.gov.in
5. www.motherdairy.com
6. www.articles.timesofindia.indiatimes.com
7. www.thirdsight.in/article/motherdairy.html

34