Report on Dairy Development Corporation (DDC) September, 2012 POKHARA UNIVERSITY

REPORT ON DAIRY DEVELOPMENT CORPORATION, KATHMANDU

Submitted to:

Submitted By

Date ..

Letter of recommendation To whom it may concern This is to recommend that the field Assessment report entitled A Field Visit to Dairy Development Corporation, Kathmandu is prepared as per the Operational Management course. This Research report has been prepared as per the work carried out under my guidance by Ankit Belbasel. The work was based on the result of own observation and the secondary data collected by him. I recommend his work for approval.

Mr. Janak Dhungana Supervisor

Department of Microbiology Tri-Chandra Multiple Campus ri-Chandra Multiple Campus Department of Microbiology Ghantaghar, Kathmandu

Date ..

Letter of approval

To whom it may concern

This is to certify that Mr. Ankit Belbase a student of B.Sc. 3rd year (Microbiology) has successfully completed the field visit to Dairy Development Corporation Balaju, Kathmandu, organized by the Department of Microbiology, Tri-chandra Campus and has submitted the report onA Field Visit to Dairy Development Corporation, Kathmanduhas forwarded to the examination.

Head of Department Mrs. Shova Shrestha Department of Microbiology Tri-Chandra Multiple Campus Ghantaghar,Kathmandu,Nepal

.. External Examiner

Acknowledgement I feel immense pleasure in presenting this report on field visit on Dairy Development Corporation Balaju, Kathmandu. This will enable the students to know the real world of work. It helps the students to apply conceptual knowledge acquired in the classroom to the real practical life. It is a great pleasure of mine to express my feeling and experiences of report writing as partial fulfillment of the requirement of B.Sc. program. My days of devotion of this field report preparation has been remarkable. At first I express my deep sense of gratitude to Mrs. Shova Shrestha the HOD of Tri-Chandra Multiple Campus for organizing the field visit program to the Dairy Devlopment Corporationn Balaju, Kathmandu and for a great encouragement, motivation and suggestion during the planning and preparation of this report. I would also like to thanks my lecturers Mr. Janak Dhungana for their support and company during the field visit. At last, I would like to express my gratitude to Mr.sandip Raj Pradhan production manager of DDC, Mr.Kriti Karki Technical Assistent, all of my teacher and my entire friend who has fully supported and encouraged me in preparing this report.

Thank you.

ABSTRACT

The main aim of the field visit to Dairy Develolpment corporation Balaju, Kathmandu was to enhance the theoretical knowledge obtained in the college by observing the different process obtain in dairy. Also observing the different test obtained in dairy lab. Different parts of the treatment plant were observed and the process was understood during the visit. During the visit the Mr.Sandip Raj Pradhan gave the detail presentation how the Milk is collected, processed and distributed to the public and Mr.Kriti Karki (Technical assistant) explain about the chemical and Biological testing. After description we obtain the field visit.

Acronyms

DDC KMSS BMSS HMSS LMSS NMSS JMSS DMSS MPCC MSNF HACCP HTST

Dairy Development Corporation Kathmandu Milk Supply Scheme Biratnagar Milk Supply Scheme Hetauda Milk Supply Scheme Lumbini Milk Supply Scheme Nepalgung Milk Supply Scheme Janakpur Milk Supply Scheme Dhangadi Milk Supply Scheme Milk producers Chilling Centre Milk Solid Not Fat Hazard Analysis Critical Control Point High Temperature- Short Time

LIST OF CONTENTS Cover page Letter of Recommendation Letter of Approval Acknowledgement Abstract List of Table List of Figure Acronymes TOPIC CHAPTER I: INTODUCT 1.1 Background 1.1.1.1 Objectives of DDC 1.1.1.2 Collection Network 1.1.1.3 Products Manufactured 1.2 Objectives 1.3 Limitation CHAPTER II: STUDY METHODOLOGY 2.1 Study Area 2.2 Data collection, Processing and interpretation CHAPTER III: OBSERVATION 3.1 Preliminary Test for Milk 3.1.1 Sampling 3.1.2 Clot on Boiling (COB) Test 3.1.3 Acidity Test 5 5 5 Page No. 1 1 1 2 2 3 3 4 4 4 5

3.1.4 Fat test 3.2 Pasteurization 3.3 Homogenization 3.4 Skimming 3.5 Chilling 3.6 Waste Management Process CHAPTER IV: RESULT AND DISCUSSION

6 6 6 7 7 7 8

CHAPTER V: CONCLUSION AND RECOMMENDATION

References

Annexes

List of Table

No. of Table Table No. 1

Heading of Topics The collection network under different Milk Supply Schemes

Page NO. 2

List of Figure

No. of Figure Figure No. 1 Figure No.2 Figure No.3 Figure Process

Heading of Topics DDC office Pasteurization Plant Packaging Process No.4 10

Page No. 10 10 10 Chilling

CHAPTER I INTRODUCTION

1.1 BACKGROUND Dairy Development Corporation established under corporation Act 2021 BS. DDC-a fully state owned corporation, initiated for the economic advancement of the poor farming communities, has flourished into a nationwide movement with an annual collection over 60 million litres of milk from more than 75 thousand milk producers through 888 milk cooperatives spread out in 33 district. With the sate-of-art infrastructure comprising of fully modern dairy plants, 11 cheeses manufacturing units, 45 milk chilling plants and highly qualified dairy specialists, DDC is a precious asset in the economic development of our nation. 1.1.1 OBJECTIVES OF DDC Provide a guaranteed market for milk to the rural farmers with fair price.

Supply pasteurized milk and milk products to urban consumers.

Develop organized milk collection system to meet increasing demand for pasteurized milk and milk products.

Develop an organized marketing system for milk and milk products in urban areas

Emphasis on quality improvement in whole chain from farm to fork.

Implement scientific milk pricing policies that encourage quality milk production.

Strengthening of farmers institutions and improving their capabilities.

1.1.2 COLLECTION NETWORK

DDC has been playing a special role in contributing to uplift the economic status of rural farmers. Thus dairy has been recognized as an effective tool for poverty alleviation. In the Fiscal Year 2065/2066 DDC purchased about (approx.) 1, 48,000 liters of milk per day from the farmers.DDC has been collecting cow, buffalo and chauri milk from 40 districts. Milk is collected through the farmers owned, Milk producers Cooperative Societies (MPCS). Its present milk collection network has spread from Panchthar in the East to Surkhet in the West including those brought from India.

Hetauda Milk Supply Scheme also supports KMSS & BMSS by supplying excess milk above their local requirement. Biratnagar Milk Supply Scheme manufactures skimmed milk powder from its excess milk and milk excess from other supply schemes. Schemes KMSS BMSS HMSS LMSS NMSS MPSS JMSS DMSS TOTAL MPCCs 281 126 167 63 40 49 25 24 791 Chilling Center 30 11 8 6 3 14 7 5 63 District Covered 7 4 3 4 4 8 6 2 34 1. Table 1: The collection network under different Milk Supply Schemes

1.3 PRODUCTS MANUFACTURED Dairy Development Corporation, a leading manufacturer of standardized pasteurized milk, full cream milk, sterilized flavoured milk (DDC Fresh), cream, yoghurt, ice-cream, yak cheese, cheese spread, kanchan cheese, mozzarella (pizza) cheese, processed cheese, paneer, ghee, yak ghee, butter, lalmohan, rasbari, peda, gudpak and Jeera butter milk.

1.2 OBJECTIVES To collect information about raw materials used and products manufactured by the corporation.

To collect information about the processes used during manufacturing of different products.

To know about the application of HACCP during the manufacturing process.

To collect information about the waste management practices adopted by corporation.

To know about the market policy of the corporation.

To know the public response about the corporation.

1.3. LIMITATION

Lack of sufficient time to explore the corporation.

Workers were not easily to interact about the corporation and their waste management process.

Related person were not available to interact during the visit to the plant.

CHAPTER II STUDY METHODOLOGY

2.1 STUDY AREA

Dairy Development Corporation, Kathmandu was selected for the industrial visit to obtain information about the different method adopted during the manufacturing process. The field visit was conducted on 25th September 2012 to obtain the information on above objectives.

2.2 DATA COLLECTION, PROCESSING AND INTERPRETATION

Field visit to the factory and the surrounding areas of the factory was carefully done. Factory workers were interviewed according to the schedule. Every phenomena and conditions was observed analytically. The journal about the industry was surfed on the internet.

CHAPTER III OBSERVATION

3.1 PRELIMINARY TEST FOR MILK

3.1.1 SAMPLING

Accurate sampling is the first pre-requisite for fair and just quality control system. Liquid milk in cans and bulk tanks should be thoroughly mixed to disperse the milk fat before a milk sample is taken for any chemical control tests. Representative samples of packed products must be taken for any investigation on quality. Sampling milk for bacteriological tests require a lot of care. Dippers used must have been sterilized in an autoclave or pressure cooker for at least 15mm at 120 C beforehand in order not to contaminate the sample. On the spot sterilization may be employed using 70% Alcohol swab and flaming or scaling in hot steam or boiling water for 1 minute.

3.1.2 CLOT ON BOILING (C.O.B) TEST

This test is quick and simple. It is one of the old tests for too acid milk (pH<5.8) or abnormal milk (e.g. mastitis milk). If a milk sample fails in the test, the milk must contain much acid or rennet producing microorganisms or the milk has an abnormal high percentage of proteins like mastitis milk. Such milk cannot stand the heat treatment in milk processing and must therefore be rejected.

3.1.3 ACIDITY TEST

Bacteria that normally develop in raw milk produce more or less of lactic acid. In the acidity test the acid is neutralized with 0.1N Sodium hydroxide and the amount of alkaline is measured. From this, the percentage of lactic acid can be calculated. Fresh milk contains in this test also "natural acidity" which is due to the natural ability to resist pH changes .The natural acidity of milk is 0.16 - 0.18%. Figures higher than this signifies developed acidity due to the action of bacteria on milk sugar.

3.1.4 FAT TEST

Milk fat is separated from proteins by adding sulfuric acid. The separation is facilitated by using amyl alcohol and centrifugation. The fat content is read directly via a special calibrated butyrometer.

3.2 PASTEURIZATION

Pasteurization is a process of heating a food, usually liquid, to a specific temperature for a definite length of time, and then cooling it immediately. This process slows microbial growth in food. Unlikesterilization, pasteurization is not intended to kill all micro-organisms in the food. While there are some few pathogens which are heat resistant, modern equipment is readily able to test and identify bacteria in milk being processed. Pasteurization is the only effective means of eliminating 90% or more of harmful organisms in milk. Diseases that pasteurization can prevent include tuberculosis, brucellosis, diphtheria, scarlet fever, and Q-fever; it also kills the harmful bacteria Salmonella, Listeria, Yersinia,Campylobacter, Staphylococcus aureus, and Escherichia coli 157. In DDC High Temperature/Short Time (HTST) process is use. In the HTST process, milk is forced between metal plates or through pipes heated on the outside by hot water, and is heated to 72 C for 1520 seconds.. Milk simply labeled "pasteurized" is usually treated with the HTST method.

3.3 HOMOGENIZATION

Homogenization is a mechanical treatment of the fat globules in milk brought about by passing milk under high pressure through a tiny orifice, which results in a decrease in the average diameter and an increase in number and surface area, of the fat globules. The net result, from a practical view, is a much reduced tendency for creaming of fat globules. Three factors contribute to this enhanced stability of homogenized milk: a decrease in the mean diameter of the fat globules, a decrease in the size distribution of the fat globules, and an increase in density of the globules owing to the adsorption of a protein membrane. In addition, heat pasteurization breaks down the cryo-globulin complex, which tends to cluster fat globules causing them to rise.

3.4 SKIMMING

Skimming is the process of lowering of fat from milk. Skim milk is a dairy product with an extremely low fat percentage. As a general rule, products labeled as skim milk have less than 0.5% fat. Most dairies pasteurize their milk products out of concern for safety. After separation into skimmilk, whole milk, and other dairy products, the milk is also usually homogenized. Skim milk also tends to have a slightly watery flavor. The separating machine at the milk processing plant measures the amount of fats in the milk and separates enough fat from the milk to meet the federal standards for skim milk.

3.5 CHILLING

The rates of most chemical reactions are temperature dependent; as the temperature is lowered so the rate decreases. Since food spoilage is usually a result of chemical reactions mediated by microbial and endogenous enzymes, the useful life of many foods can be increased by storage at low temperature. Chilling means storage of the foods at temperature near, but above their freezing point, typically 0-5C. Chill storage can change both the nature of spoilage and the rate at which it occurs. There may be qualitative changes in spoilage characteristics as low temperatures exert a selective effect preventing the growth of mesophiles and leading to a microflora dominated by psychrotrophs.

3.7 WASTE MANAGEMENT PROCESS Waste management comprises of powerful and systematic control of generation, storage, collection, transport, separation, processing, recycling, recovery and disposal of wastes. The process adopt 3R concept that include reduce, reuse and recycle, also termed as integrated approach to waste management.

CHAPTER IV

RESULT AND DISCUSSION Dairy Development Corporation (Kathmandu) located at Balaju was visited and the processes applied in the Corporation for the manufacturing the milk and its different products were known. A round table conference was also organized so as to discuss the entire processes involved during the manufacturing. The milk were used to be collected from different region was brought to the Corporation. On arrival, preliminary as well as microbiological examinations of the milk were done. After passing each test the milk were sent to the plant for further processes. The general discussion outline drawn includes: 1. Pasteurization process performed was HTST, which was performed at 72C for 15-20sec.

2. Critical control points criteria were established during primary chilling process, transportation and pasteurization only.

3. Different products were manufactured by the corporation which wasnt sufficient to fulfill the market demand.

4. The major waste from the plant was water and the plastics which were used for washing and packaging purpose respectively.

CHAPTER V CONCLUSION AND REOMMENDATION

CONCLUSION

The main purpose of the visit to Dairy Development Corporation, Kathmandu was to observe the process used to manufacture the milk and milk products and other similar process required for our report. It is concluded that the corporation was the backbone of Nepal in the field of milk and milk products market. Though the corporation has been while established but it lack proper site related to the field of microbiology and waste management process.

RECOMMENDATIONS

Some recommendation how the corporation can be effective are listed below:

Establishment of proper Critical Control Point criteria. The waste generated by the corporation needs to be properly managed. Products quality should be checked on regular basis. Public should be encouraged towards the milk farming in order to fulfill the market demand.

REFERNCES

M.R. Adams and M.O. Moss (2009); Food Microbiology, New Age International (P) Limited, Publishers Official site for Dairy Development Corporation. www.google.com

PHOTOGRAPHS

Fig1: DDC Products

Fig2: Pasteurization plant

Fig3: Packaging process

Fig 4: Chilling process