A Case study on BCMPUL based on 4 days exposure cum training visit

Topic: Being a cooperative organisation designed systematically to feed the feeder dairies commissioned in
1989, and considering the economical condition, emphasize the scope for expansion and modification to
compete with the existing market. Chalk out the necessary plans required for processing and quality area as
well as its maintenance as per current legal norms.

1. Whey utilisation: As there is no so-called ETP plant in the dairy and the whole paneer whey
is disposed in the waterbody nearby, it will increase the microbial load as well as the BOD of
the lake to a huge extent. This is a major flaw when the plant is thinking from the point of
view of getting ISO 22000:2005. Hence, it is better to use the whey for manufacturing of
some new products or by blending it with lassi which will reduce the milk requirement for
lassi and will also increase the palatability.
2. Insulated Tunnel Line to Cold storage: As the tunnel line through chain conveyor is fully
exposed to the outside environment, there is a major temperature shock that the milk
pouches experiences, especially during the time of summer, thereby increasing the load of
cold storage room and hence huge loss of energy. Hence, it is necessary to cover the
conveyor line and to make it insulated so as to protect it from environment and also from to
hot blower outlets above the tunnel line.
3. Perforated crate: As we know, the temperature of cold storage room is only 7°C which is not
enough, hence efficient methods must be adapted to comply with the deficits present. This
includes use of PERFORATED CRATES for Dahi, stacking it in a Criss Cross pattern and
introduction of at least two new blowers can help in uniform and fast cooling.
4. Changing of resins of the soft water plant after every 6 months instead of 3 years.
Implentation of RO System is also necessary.
5. CIP changes required: It is best to introduce Loop CIP Mechanism for every sections. temp at
return pt.
To introduce a new CIP centrifugal pump for Dahi packaging machine
to increase the flow rate of the CIP solutions and thereby improving the quality of pouch
dahi, instead of gravity flow CIP.
Keep the record of CIP for every section amt, str and temps and every
equipments.
Taking of swabs from FFS machines everytime to ensure proper CIP
and sanitization before starting any batch.
6. Cover the roof of packaging section with opaque material instead of translucent fibre glass
to prevent sunlight falling on the packaging machine and milk on the FFS milk bowl.
7. Taking the initial and final weight of the packaging film roll and find yield to reduce the
packaging film loss.
8. Covering the milk dump tank at RMRD with openable SS lids will prevent contamination to
the nearby packaging section and will also prevent the bird droppings.
9. Utilisation of GHEE RESIDUES to reduce economical loss.
10. Introduction of Turbo-blender in dahi section for uniform blending of SMP in Dahi milk as
there is no homogeniser available.
11. Prevent cats and dogs to enter the paneer vacuum packaging area.
12. To spread awareness of proper PERSONAL HYGIENE among all workers and employees of
plant.
13. Prevent ammonia leakage from the refrigeration section.
14. LAMINAR AIR FLOW should be introduced.
15. Daily Adulteration Check, Proper sampling plan according to fssai.