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Submitted by:

Nishant Sachdeva
L-2010-A-03-B.tech FT
Industrial Training
The Ludhiana District Co-operative Milk
Producer's Union Ltd.
Introduction
First Milk Plant, of the State was setup at Verka near Amritsar.
The brand name of Milk and Milk Products was adopted as
Verka.
The Foundation stone of Milk Plant, Ludhiana was laid by Hon.
S. Parkash Singh Badal, the then Chief Minister of Punjab in
1970.
Commissioning of the Plant was done by Punjab Dairy
Development Corporation in 1974.
Inauguration was done by Late Smt. Indira Gandhi the Prime
Minister of India.
The capacity of the plant was 1.00 lac. Litre per day, and now
the milk handling capacity is 4.00 Lac Liter per day.
MILKFED PLANTS LOCATION
MILKFED has its milk unions in almost all the districts of
Punjab. These district units are:-
Horshiarpu
Amritsar r
Bathinda Jalandhar
Chandigarh Ludhiana
Faridkot Patiala
Ferozpur Ropar
Gurdaspur (Mohali)
Sangrur

These plants in all these unions are being run under the
Present Status
No. of societies increased from 94 to 802 and its membership
from 5400 to 78500.
Milk Procurement has increased from 10200 LPD to 2,50,000 LPD.
Highest milk price is being paid to the milk producers as
compare to other plants in the states
Products being manufactured by Ludhiana Plant are sold at
premium rates through out of the country and in the
International Market.
City supply has increase from 66000 LPD to 1,98,000 LPD.
Turnover the plant touched to 283 crores Profit of the union has
increased manifold.
Capacity utilization of the plant is more than 85%.
VERKA MILK PLANT -
Full name
PROFILE
: The Ludhiana District Cooperative Milk
Producers Union Ltd.
Foundation : Laid by Hon. Sh. Prakash Singh Badal in 1970
Capacity : Then 1 lakh L/day, Now 6 lakh L/day
Head office : Punjab State Co-operative Milk Producers
Federation Ltd. S.C.O.153-155, Sec. 34-A, Chd.
Inauguration date : 31stOctober, 1974
Chairman : Sh. Ajmer Singh
No. of societies : 816
No. of Chilling centers : 4
Brand name : VERKA
Products marketed by : The Punjab State Co-operative Milk Producers
Federation. Ltd.
Quality certificates : International Quality Certificate ISO-9002 & IS-
15000 (HACCP)
VERKA MILK PLANT
Verka milk plant (VMP), Ludhiana is known as The Ludhiana Dist.-
Co-operative Milk Producers Union Limited, Ludhiana . It is situated
on Ferozpur Road, about 5 km. away from both railway station and
main bus stand.
The plant has bagged first position in Northern Zone

It is fully equipped with modern fluid milk plant facilities. The latest
state of art technology in milk drying is available in this plant.
The products manufactured by this Plant at present are STM, DTM,
FCM, SMP, WMP, Ghee, Butter, Paneer, Milk-Cake, Dahi, Kheer, Lassi
.

Contd
VERKA MILK PLANT
Some objectives of the Milk Plant are:-
To uplift social and economic status of milk producers.
To develop dairy as industry allied to agriculture.
To provide better and remunerative prices for milk.
To provide veterinary aids to animals of milk producers at
their doorstep.
To provide better quality cattle feed at reasonable rates.
To educate the milk producers about lowering down the
cost of milk without compromising quality.
To create employment opportunities for rural youth by milk
production activities.
To provide awareness among milk producers for socio-
economic change through co-operative set-up.
PRESENT STATUS OF VMP
Product brand name : VERKA
Milk handling capacity : 6 lakh litres per day
Production of market milk : 2.5 lakh litres per day
Production of butter : 13000 Kg per day
Production of ghee : 14 MT per day
Production of powder : 30 MT per day
Production of paneer : 400-450 Kg per day
Production of kheer : 200 Kg per day
Production of milk cake : 30-40 Kg per day
Production of dahi : 1400 Kg per day
Production of lassi : 3000 Kg per day
POWDER SECTION
There are definite indication of greater future
productions of dried milk & milk products due
to their better keeping quality, they require
less storage space & lower transportation
costs. All these are economically attractive.
Dried milk provides a means of handling the
excess milk supply in a dairy factory during
flush season, while in lean season that meant
for the production of dry milk can be diverted
to market milk. Thus, dried milk is called the
balance wheel of dairy industry.
VERKA MILK PLANT, LUDHIANA has two
separate drying plants.
POWDER SECTION
The Dairy has two separate drying plants, viz:
Powder section with MVR unit & TVR unit (30TPD)
Powder section with TVR unit only (6.5TPD)
Compositional & other Standards maintained :-
Parameters SMP Standard SMP Extra WMP
grade grade
Moisture (%) 3.2-3.6 3.0-3.4 Max. 3
FAT (%) Max. 1.3 Max. 1.2 26.5-27.5
Acidity (%LA) 1.0-1.25 1.0-1.2.5 Max. 1
B.D. Agglomerated (gm/ml) 0.45-0.55 0.5-0.6 0.5-0.6
Insolubility Index (50ml) Max. 0.15 Max. 0.15 Max. 0.5
Ash content (%) Max. 8.2 Max. 8.2 Max. 0.5
Coliform Nil Nil Nil
PROCESS CONTROL
Lumpiness in Powder

1. Ensure proper cooling of powder

2. Dehumidifier should be properly


operating
Low moisture in Final Product 1. Increase flow rate

2. Adjust outlet temp


Burnt Powder Particles 1. Adjust inlet temp

2. Check the function of feed flow controller


& feed pump

3. Nozzle of jets are whether chocked


partially
Sooty Powder 1. Clean or change the filter.

2. Check up air heater


Very Fine Powder A Particles 1. Increase in degree of concentration

2. Control the feed temp.


Solubility Index Increased 1. Check the outlet temp.

2. Control feed rate


OPERATING PARAMETERS FOR EVAPORATING
PLANT
PARAMETER STANDARD & EXTRA W.M.P CONCENTRATED MILK
GRADE
Milk feed rate (lts/hr) 16000-17000 3500-14500 16000-17000
Steam pressure 5-6.5 5-6 5-6.5
(kg/sq.cm)
Thermal vapor 2-2.5 2-2.5 1-1.5
recompression
(kg/sq.cm.)
High heater (temp oC) 90+/-2 95-100 90+/-2
Holding heater temp -Do- -Do-` -Do-
(oC)
Flush vessel temp 73-85 73-85 73-85
(oC)
Jacket temp (oC) 69+/-1 69+/-1 69+/-1
Vapor Separator I (oC) 66+/-2 66+/-1 66+/-1
Vapor Separator II 58+/-2 58+/-1 58+/-1
(oC)
Vapor Separator III 50+/-2 50+/-1 50+/-1
(oC)
Vacuum in condenser 0.9m bar 0.9m bar 0.9m bar
T.S. % of condenser 20+/-3 20+/-3 20+/-3

OPERATING PARAMETERS FOR DRYING PLANT

PARAMETERS SMP WMP


Chamber inlet air 170+/-10 165+/-5
temperature (oC) 180+/-10 170+/-5

Vibro fluidier air inlet 90+/-5 65+/-10


temperature (oC)
Chamber outlet temperature 80-90 80-90
(oC)
Vibro fluidier outlet 64+/-2 65+/-2
temperature (oC)
Chamber vacuum (mm.w.c) 5+/-2 15+/-2
Atomizer load (amp) 55+/-5 55+/-5
Load on exhaust fan (amp) 95+/-5 95+/-5
Powder output (kg/hr) Min. 1375 Min. 1500
Powder Plant
Drying Chamber

Cyclone
Control Panel
Processing Operations

Chilling: Milk is chilled below 4 C. The


raw chilled milk is utilized for the various
products processing operations. The
chilled milk is stored in tank called as
Silo. The chiller is plate heat exchanger
type.
Pasteurizing: Milk is heated at 63 C for
30 minutes or 75-80 C for 15 sec and
then cooled immediately below 14 C.
RAW MILK RECEPTION DOCK (RMRD)
Make : Cast iron grid tiles, edges are of cast iron planting
Width : To overcome heavy stresses
Types : 1.5mm
Slope : Open

Cans : 40 Liters capacity, weighing 6-6.5 kg


Material : Aluminum

Type of milk received :-


Cow Milk :- Fat Min. 3%, SNF Min. 7.9%
Buffalo Milk :- Fat Min. 6%, SNF Min. 8.6%
Mixed Milk :- Fat Min. 5.4-5.5%, SNF Min. 8-8.5%
OPERATIONS AT RMRD
Starting the RMRD
Unloading and Conveying
Opening the lids
Grading
Weighing and Sampling
Cleaning & Washing of cans
Recording of cans
Loading
Closing down RMRD
PRODUCTION
SECTION
Composition of Milk
Characteristic Cow milk Buffalo milk

Fat 4.0-4.5 % 6.5-7.0%

Carbohydrates 4.5 % 4.7 %

SNF 8-8.5 % 8.5- 9.0%

Proteins 3.3 % 3.6 %

Minerals 0.6 % 0.7 %

Water 87-88 % 84-85 %


PRODUCT FLOW
City Supply Section
PANEER SECTION

Compositional & other Standards maintained :-

Equipments used are- Steam Jacketed Vat, Trolleys, Sealing Machine, Hoops,
Automatic Machine For Processing.

Cleaning of vats, hoops & muslin cloths is done manually, then they are
sanitized with 0.5% teepol & hot water at 55-60oC

Fat Not < 50% of dry


mater basis
Moisture Not > 70%

Texture Soft & spongy

Taste & flavor Pleasant


Flow diagram for Paneer
manufacture
Dipped in
Cutting into pasteurized &
Whole milk chlorinated
blocks
chilled water (4-
10oC/45-60 min)

Heating (90oC) Cut into pieces


Pressing & weighing
for 15 min
(200gm
manually)

Filtration (with
clean muslin Hoping Packing in
cloth) polythene
sachets

Coagulation (1- Separation of


2% citric acid) whey Storage at butter
cold store Dispatching
DAHI SECTION
This dairy plant follows the ISI standard of dahi. Mostly it is manufactured
every two alternate days in flush seasons.

Compositional & other Standards maintained :-

Fat 4-5%

Protein 3.2 -3.4%


Acidity 0.8-1.0%
Taste Cream-sour
Flavor Acid

Equipments used are- Steam Jacketed Vat, Weighing Balance, Cans, Incubation
Chamber, Dahi Packaging Machine.
Flow diagram for Dahi manufacture

Milk is taken in Putting 12 Cups


Incubation
Vat For Dahi in each Card
(37oc/1.5-2hr)
Preparation Board Box

Standardization
& Sealing the Cups Dahi Prepared
Homogenization

Pasteurization Filling by pipe


Cooling &
(80-90oc/15-30 filler in
Storage (5oc)
Min) polystyrene cups

Inoculation with
Lactic Culture
Cooling (37C) Dispatch
(from previous
day Dahi)
BUTTER SECTION
Ludhiana milk Plant is engaged in making two types of butter viz

Table Butter

White Butter (White Butter is made and stored as stock and is


used in lean season for recombination and is also used as base
material for ghee & often supplied for bulk demand).

The dairy produces butter by batch churn method. There is


also a provision for continuous butter making machine.

The packed butter is stored at -17 to -29oC till dispatch.


Operating Parameters for Table Butter

Loading of churn 1/3rd volume of drum capacity


Loading temp (oC) < 10-12 oC
Churning temp (oC) < 10-12 oC
Color addition 1ml/kg fat
Spray water temp (oC) Max 5
28-30 rpm (1st gear)
Speed of churning 14-18 rpm (2nd gear)
7-8 rpm (3rd gear)
Salt addition (dissolved in pasteurized warm
22mg/kg of butter yield
water)
Vacuum during operation 300-350mm
FAT % in cream 40-42
Flow diagram for Table Butter manufacture
Washing at 2nd Equal in
Cream from gear (6-8oC/15 volume of Package in card
separator min after buttermilk board boxes
adding water) removed)

Cram Removal of Draining of Storage (-17 to


pasteurization buttermilk water -29oC)

Storage in Churning at 4th


Packaging (500,
cream tank for gear of white 2nd washing
100, 10 gm)
ageing butter

Unloading
Churning at 2nd Salt @ 2.2% is
Feeding to (before it rotate
gear (30-45 added (for table
butter churn at 2nd gear for 5
min) butter)
min)

(In case of table Churning at 1st Working &


butter color is gear up to controlling of (25-30 min.
added @ breaking point moisture at 2nd 300-350mm)
1ml/kg/fat) (30-35min) gear
GHEE SECTION
Compositional & other Standards maintained :-

Flavor & color Pleasant & white or yellow


Moisture Max. 0.25%
F.F.A (% Oleic Acid) Max. 0.03%
B.R. reading at 40oC 40-43
Peroxide value Max. 1
Sediment Absent

Equipments used are- Butter Melting Vat, Pre-stratification Tank, Ghee Boiler,
Settling Tank, Filling/Storage Tank, Ghee Clarifier, Electronic Weighing Balance,
Closure Punching Machine, Pouch Filling Machine.
Operating parameters
Pre-melting temp (oC) 75-80
Cooking temp (oC) 105-112
Batch time (hr) Max. 4
Steam pressure in kettle (kg/sq.cm.) 2
Filtration Falalin cloth
Clarification temp (oC) 95+/-5
Setting time (hr) Min. 6
Ghee filling tank temp (oC) 43+/-5
Ghee filling temp (oC) 42+/-5 C
After packaging the packed corrugated boxes are kept in
granulation room for 24 hrs. Then the boxes are transferred into
storage room till dispatch.
LASSI : Lassi is a drink made of standardized milk with
50:50 dilutions with water.

Receiving Cold storage less than 5c


milk

Packaging
Standardization
(4.5%fat and
8.5%snf) Breaking of coagulum
( acidity o.54%)
Heating of
milk
85c /5min Addition of pasteurized
chilled water 2%
Cooling down to 40c

Inoculation at 40 c
culation with culture at 1% at 40 c(till acidity reach 0.67%)
Kheer is concentrated heat desiccated
indigenous dairy product.
Any question ?

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