KATRAJ DAIRY

INTRODUCTION
Our college coordinator Mrs. Pinky Agarwal organized an industrial visit to Katraj Dairy on the 5th of February 2011. It was a very well organized day trip to the dairy. Where we got a chance to study the various steps and procedures involved in the purification of milk and the manufacturing of various milk products.

KATRAJ DAIRY- PAST TO PRESENT

Katraj Dairy was incorporated in 1960 with an intension of providing an organized facility of milk collection for the village level farmers situated in Pune district. Katraj Dairy started with milk collection of about 0.30 lakh (30.000) liters per day in the first year of operation and today, has steadily grown to over 1.50 lakh (0.15 million) liters per day and has a financial turnover of over Rs.150 crores (US$ 33 million). Katraj Dairy has achieved ISO 9001:2000 & HACCP certification from DNV in Oct. 2006 & maintained. In Oct. 2009 Dairy has achieved ISO 9001:2008 & HACCP 2006 Dutch Standard from Dr. Norskey Veritus. Katraj Dairy with its eight chilling plants and 12 BMC spread almost all over the district has an installed milk handling capacity of over 5 lakh (0.50 million) liters per day. The main plant of Katraj is equipped with modern Pasteurizer, homogenizer, Cream separator, Ghee processing, automatic packing of milk and milk products and other

quality testing devices and well equipped labs. Katraj Dairy has an installed processing capacity of 2 lakh (0.2 million) liters per day. Katraj dairy manufactures / Distributes milk and milk products like Pasteurized/ Homogenized-Cow milk, Toned milk, Double toned milk, Standardized Milk, Full cream milk, Cow & Buffalo Cream and Ghee, Shrikhand, Amrakhand, Malai Paneer, Dahi, Flavored Milk, Lassi, Jeera Tak, Table Butter, Milk Powder, Softy Ice cream, pedha, Khoa and in the near future plans to introduce sterilized milk in 200ml bottle and hard ice-cream with different flavors in different pack sizes. All these products are available at Katraj owned parlors at various locations in Pune City and through appointed distributors and retailing circuits. Very soon, Katraj plans to introduce an online ordering system for its distributors/ retailers and consumers. Katraj products have been in use in thousands of homes in Pune since 1961. Katraj Milk, Katraj Ghee, Katraj Shrikhand, Katraj Amrakhand, Katraj Lassi, Katraj Jeera tak (buttermilk), Katraj cream have made Katraj a leading food brand in Western Maharashtra. Today Katraj is a symbol of high-quality milk products sold at reasonable prices, the genesis of a vast co-operative network triumph of indigenous technology, the marketing savvy of a farmers' organization.

OBJECTIVES OF KATRAJ DAIRY

The objectives of Katraj Dairy are, to build a valued chain of farmers to source milk at an organized level, manufacture products at a very high quality level and create a demand for their products in the competitive market without having any reasons to be pointed at. This organization has a unique advantage, its strategic location. Based in Pune city, a place with historic, cultural importance and a major district in Maharashtra, India. The city is known as the city of students because of its large number of educational centers. Another major advantage is that Mumbai is just 180km. away. Thus using these key factors, they want to serve the state with their superior quality of milk. They want the state to crave for this superior quality of milk.

THE FARMERS & KATRAJ DIARY

Prior to Katraj Diary, farmers use to sell their milk to middlemen. These middlemen were never trust worthy as the farmers milk was always adulterated with water, promises that were never fulfilled, the true price at which the milk was sold was never known and the farmers didnt get their money most of the time, if they ever got it at all. Although the farmers didnt like this system, they didnt have a choice, as there were no other alternatives. However, as Katraj Dairy came along, a new picture was painted. Katraj simplified this system to eliminate the problems of the farmers and create a win- win situation for both of them. Katraj strategically placed collection centers in the middle of the villages. Thus

making it very convenient for the farmers to contribute their milk. Further more, the farmers are paid their money on the spot, based on quality and quantity of milk. This also creates a meeting point for all the farmers to discuss various new methods and techniques to increase their cattles milk producing capacity. It also gives the farmers a sense of pride, as they can be proud of the quality of milk being produced by their cattle.

HOW DOES KATRAJ DAIRY HELP THE FARMERS?

The collection centers pay the farmers for their milk on the spot based on quality and quantity of milk. Because of which the farmers dont have to wait on their money. Katraj teaches and educated the farmers with new dairy technologies, thus keeping them up to date with a global market. Katraj also provides the farmers with vitamins for their cattle, to receive a better quality of milk. They also teach the farmers what type of fodder is to be fed to the cattle when. They also provide medical assistance for the cattle, to their limit. Katraj is also trying to promote organic/green milk. Organic milk is basically milk from cows that have been exclusively fed organic feed, have not been treated with synthetic hormones, are not given certain medications to treat sickness, and are held in pens with adequate space.

PRODUCTS PRODUCED AT KATRAJ DAIRY

MILK Milk is an almost ideal food. It has high nutritive value. It supplies bodybuilding proteins, bone forming minerals and health giving vitamins and furnishes energy giving lactose and milk fat. Besides supplying some essential fatty acids, it contains the above nutrients in an easily digestible and assailable form. All these properties make milk an important food for pregnant women, growing children, adolescents, adults, invalids, convalescents and patients alike.

Milk may be defined as a whole, fresh, clean, lacteal secretion obtained by the complete milking of one or more healthy Milch animals excluding that obtained within 15 days before or 5 days after calving or such periods as may be necessary to render the milk practically colostrums free and containing the minimum prescribed percentage of milk fat and milk-solids-not-fats.

Pasteurization: The term pasteurization refers to the process of heating each & every particle of milk to at-least 63 C for 30 minutes, or 72 C for 15 seconds in approved and properly operated equipment. After pasteurization the milk is gradually cooled to 5 C or below.

Homogenization: Homogenization refers to the process of forcing the milk through a homogenizer with the object of sub dividing the fat globules.

CREAM When milk fat is concentrated into a fraction of the original milk, that portion is known as cream. Cream is a rich portion of milk fat. Cream is the product of cow or buffelo milk or a combination thereof, which contains not less than 25 % milk fat.

Various Types of Cream Table Cream Light Cream Coffee Cream Whipping Cream Heavy Cream Plastic Cream Containing 65 - 85 % milk fat } Containing 30 - 40 % milk fat } Containing 20 - 25 % milk fat

Katraj Dairy has been manufacturing plastic cream with 65 - 75 % milk fat.

GHEE

Ghee is the pure clarified fat derived solely from milk or from desi (cooking) butter or from cream to which no coloring matter is added. Ghee is the clarified butter fat prepared chiefly from cow or buffalo milk. Ghee is used as a cooking or frying medium, in confectionary, for direct consumption with rice chappatis etc. Cow ghee is mainly used in indigenous pharmaceutical preparations (Ayurveda).

Packing Sizes:

500 gm. Poly pack. 500 ml standy pouch. 15-liter tin.

 SHRIKHAND Shrikhand is a semi-soft sweetish - sour whole milk product prepared from lactic fermented curd. The curd (dahi) is partially strained through a cloth to remove the whey and thus produce a solid mass called chakka (the basic ingredient for shrikhand). This chakka is mixed with the required amount of sugar, cardamom, jaiphal etc. to yield shrikhand.

Packing Sizes: 100 ml plastic cups 250 ml plastic cups 500 ml plastic cups

For Party or catering purpose available in loose bulk sale.

Best for occasions like Gudhi Padwa, Raksha bandhan, Dasara, Diwali etc.

Direct consume with Puri, Chapatti, for better test.

 AMRAKHAND Amrakhand is a semi-soft sweetish - sour whole milk product prepared from lactic fermented curd. The curd (dahi) is partially strained through a cloth to remove the whey and thus produce a solid mass called chakka (the basic ingredient for shrikhand). This chakka is mixed with the required amount of mango flavour, sugar, cardamom, jaiphal etc. to yield Amrakhand.

Packing Sizes: 100 ml plastic cups 250 ml plastic cups 500 ml plastic cups For Party or catering purpose available in loose bulk sale.

Best for occasions like Gudhi Padwa, Raksha bandhan, Dasara, Diwali etc.

Direct consume with Puri, Chapatti, for better test.

MALAI PANEER Paneer refers to the milk solids obtained by the acid coagulation of boiled whole milk & subsequent drainage of whey. The acids commonly used are citric in both natural & chemical forms. Traditionally paneer has been a variety of pressed channa, used mainly in preparing cooked vegetable dishes like palak paneer, paneer butter masala etc.

Packing Sizes:

200 gm rotogravure laminated pouch. 500 gm rotogravure laminated pouch. 1000 gm rotogravure laminated pouch

 DAHI Matka Dahi is a fermented milk beverage. Dahi originally was set using mud pots since ancestral days for the purpose of getting that unique flavour & taste gained due to the porous property of mud pots allowing filtered air flow. But now a days dahi prepared from milk faormenting with lactic culture & packed in plastic cups 370 C.

Packing Sizes:

100 gm. matka. 200 gm. matka. 100 gm. plastic cup. 200 gm. plastic cup. 400 gm. plastic cup

 FLAVOURED MILK Flavoured Milks are milks to which some flavours/ colours and suger been added.When the milk is used the product should contain a milk fat % at least equal to the minimum legal requirement for market milk, but when fat level is lower(1.2%) , the term drink is used.

Packing Size: 200 ml Poly bag

 LASSI Lassi is a fermented Milk beverage popular in all parts of India. The technology of lassi making is however confined to only households. Lassi has a great potential in the Indian Market.

Packing Size: 200 ml Poly pack

 JEERA / PLAIN TAAK (BUTTERMILK) Tak is also called chhas or mattha, refers to desi buttermilk. It is a popular drink during the hot Indian summers, as it helps reduce body heat and lower the body temperature. Thus a relaxing drink enjoyed by everyone.

Packing Size: 200 ml Poly pack

 TABLE BUTTER For years together, table butter is being cherished as a tasty food, popularly eaten with bread. It also forms a good topping on indegeous food like Pav-bhaji, Thalipith (Pan Cake). Katraj Table Butter is marketed by Katraj Dairy Manufactured By Dynamix Dairy Industries Ltd., Baramati, Maharashtra, India.

Packing Sizes: 100 gm.

500 gm.

SOFTY ICE- CREAM This product is marketed in a soft condition and is ready for

consumption shortly after it is drawn from the freezer. Katraj dairy has soft churner in their milk factory in the Pune city.

Among milk products ice cream is also rich source of calcium, phosphorus and other minerals of vital importance in building good bones and teeth. It is a very desirable food item for growing children and person who need to put on weight. It is excellent source of Vitamin A, good source of Vitamin B & G, Niacin, and Vitamin E. The digestibility & palatability of ice cream is also very high.
Packing Size:

60 ml cone

PEDHA Pedha is preparred using khoa based material. Khoa is mixed with suger and then heated in a kadhai made of food-grade metal.After heating desired flavouring and nuts are added to the pedha mass.

Packing Sizes: 1 kg box

500 gm. box 250 gm. box

 ICE CREAM Ice-Cream may be defined as frozen dairy product made by suitable blending & processing of cream & other milk products, together with sugar & flavor, with or without stabilizer or color & with the incorporation of air during the freezing process. According to PFA rules Ice-Cream is the frozen product obtained from cow or buffalo milk or a combination there of or from cream and or other milk products with or without addition of cane sugar, fruit, fruit juices, preserve fruits nuts, chocolate, edible flavors & permitted food colors.

Nutritive Value; Among milk products, Ice cream is also a rich source of calcium, phosphorus & other minerals of vital importance in building good bones & teeth. Being rich in Lactose, Ice-Cream flavor greater assimilation of calcium in the diet. The protein content of Ice Cream is also rates high, both in quantity & quality. Ice Cream provides valuable proteins in a very palatable form. In fact, Ice Cream is most palatable source of milk protein to the vegetarians. Ice Cream is an

excellent source of food energy. It is a very desirable food item for growing children & persons who need to put on weights. Ice-Cream is a rich source of many essential vitamins, without which normal health & growth cannot be maintained. Thus it is an excellent source of vitamin -A, a good source of vitamin -B (Thiamine) & G (Riboflavin) & a fairly good source of Niacin, vitamin - E & in fruit Ice Cream of vitamin -C. The digestibility & palatability of Ice Cream is also vey high. Flavors;

Packing Sizes: 50 ml plastic cups 100 ml plastic cups 500 ml Family pack 1000 ml Party pack 2000 ml Party pack 4000 ml Bulk pack

STERILIZED FLAVORED MILK Sterilized milk may be defined as milk, which has been heated

to temperature of 1210C for 15 minutes. The Milk fit for human consumption for at least 120 days at room temperature.

Flavors;

Packing Sizes: 200 ml Glass Bottles

 KATRAJ AQUA (MINERAL WATER) Katraj Dairy with their well-known products now introducing mineral water with katraj brand i.e. Katraj Aqua. Water in its purest form is really a life giving liquid. Katraj Aqua (to live a healthy family life) gives the assurance that each drop of water that you consume is full of energy & freshness. Our dairy is also an ISO- HACCP 9001-2008 certified Dairy and it stands testimony to the quality of product. We strictly follow the quality measures regarding hygiene and quality of products.

Packing Sizes:

500 ml Bottle - packed in 24 bottles in 1 box.

1 liter Bottle- packed in 12 bottles in 1 box.

MANUFACTURING PROCESS
Initially, the milk is collected in the collection centers in the villages. This where all the villagers come and sell their milk to Katraj Dairy. After which, the milk is transported to the Katraj plant, situated in Katraj, Pune. The milk is transported in special vehicles designed for the sole purpose of milk transportation.

[MILK TRANSPORTAION VEHICLE] Once the milk has reached the plant, it is first checked for its quality. After which it is primarily filtered and added to the holding

tanks. After which the milk is transferred through pipelines to the boiler unit. This is where the milk is the milk is boiled to kill germs and make the milk last longer, known as pasteurization.

[BOILER ROOM] Pasteurization refers to the process of heating each & every particle of milk to at-least 63 C for 30 minutes, or 72 C for 15 seconds in approved and properly operated equipment. After pasteurization the milk is gradually cooled to 5 C or below.

[REFRIDGERATION DEPARTMENT] After this process the milk is stored in its specially designed storage containers. After which it is ready for further processing and packaging. The milk can be further be utilized in the production of rest of the products like flavored milk, ice cream, butter, ghee etc.

[STORAGE TANKS]

QUALITY CONTROL
Katraj Dairy is very strict when it comes to the quality of the milk and its products. It strictly maintains its standard as per ISO 9001:2000 regulations. The work of this department begins, as soon as the milk enters the gates of the factory. They initially check the quality of the milk when it is in the milk tanker or milk transportation vehicle. They do so to ensure that the milk is not spoiled and does not match the

standards of Katraj Dairy. This process is carried out to ensure that; bad milk does not get added to the rest of the milk in the storage units.

This department uses the method of random sampling for selection of samples to test. It picks up random samples from all the batches of products produced. If even one product in the batch is not up to the mark, the entire batch of the product produced is discarded. This department uses a variety of testing methods for the various products that are produced at the plant. They usually check for pH, fat, acidity, water content, saturation levels, lactic acid, etc. A hew of the chemicals that they use for testing are given below Iodine Solution Sodium Bicarbonate Lactic Acid Diastix Silver Hydroxide

PACKAGING
Katraj Dairy carries out a very simple form of packaging. It is appealing to the consumers eyes even if they are from a metropolitan city or a local village in Maharashtra. All of their packaging has the local dilet, Marathi on them along with the universal language, English.

[MILK PACKAGING] The packaging is done in a very hygienic environment. All the workers that come in contact with the products have hair caps and gloves on their hands. They also have a special uniform that has to be worn. The packaging of all the milk except the flavored milk is done in polythene bags. The bags are manufactured in other parts of Maharashtra and are inserted into the packaging machines. The flavored milk is packaged 200 ml. glass bottles. Ice cream is packaged in plastic cups as well as cardboard boxes.

DISTRIBUTION
Katraj Dairy has a simple of chain distribution. They follow two chains of distribution,
1. Manufacturer 2. Manufacturer

[CONTAINERS IN, WHICH MILK IS DISTRIBUTED]

A list of distributors that are located in and around the city of Pune, are given on the next page-

NAME OF DISTRIBUTOR AND AREA OF DISTRIBUTION Gurukrupa Associates Deepali V. Bhadale) (Mrs. Sinhagad Road, Bibavewadi to Swargate Swargate to Shivajinagar, Ghorpadi, Mundhava, Hadapasar Market Yard, Kondhava Gaon,Undari, Satav Nagar Mahadeonagar, Urali devachi Vanwadi gaon, Salunke Vihar, Manish Park Pune Camp, Nana Peth, Bhavani Peth, Koregaon Park Yerwada, Kalyani nagar, Vadgaonsheri, Viman nagar, Vishrantwadi, Dhanori Renghill Corner, Bopodi, Khadaki, Dapodi, C.M.E., Sangavi, New sangai Gokhalenagar, Chaturshrungi Payatha, Paud Phata, Jaibhavani Nagar to Chandani Chowk Yerandavana, Karve Nagar, Varaje, Uttam nagar, Kotharud gaon Rakshak Nagar, Sathe Pimple, Kalewadi Phata, Wakad, Dange chowk, Tathawade, Ravet, Punawale

Kaniphnath Milk Agency (Shri. Balasaheb V. Gavhane) Shivam Milk Agency Sandeep U. Ghate) Balaji Milk Agency Sanjay R. Ambekar) Assa Associates Amarpalsing Badh) Om Sai Distributors Anil S. Londhe) (Shri.

(Shri. (Shri. (Shri.

Sidhdheshwar Milk Agency (Shri. Sagar K. Shelake) Shevantai Milk Suppliers (Shri. Ravindra D. Takke) Sayali Milk Suppliers (Saui. Vaishali K. Gopalghare) Shriraj Milk Agency (Shri. Rajendra J. Bhargude)

Yamuna Traders(Shri. Ramesh B. Kasarwadi, Pimpari,Kalewadi Phanse) Dattakrupa Enterprises (Shri. Subodh N. Kale) Vyankatsh Milk Agency (Shri. Rohidas K. Lawande) Vivek Vasahat, Shridhar Nagar, Sudarshan Nagar, Udyog Nagar, Bijali Nagar, Chinchwad Gaon Akurdi Gaon, Akurdi-Nigadi Pradhikaran,Dehuroad, Talegaon Dabhade,Kamshet, Lonawala

Rudra Enterprises (Sau. Chhaya C Sant Tukaram Nagar, Ajamera, Jagtap) Neharu Nagar, Balaji Nagar, Indrayani Nagar, Landewadi, Bhosari Gaon Kunal Milk Agency (Shri. Rahul D. Takke) Shri Saikrupa Distributors (Shri. Amod B. Pandhari) Radha Krishna Milk Agency (Shri. Sandip D. Chambhare) Pashan, Sutarwadi,Bavdhan, Boys Batalian, Aundh gaon Someshwarwadi, Sanewadi,Parihar chowk, Dattanagar, balewadi, Hinjwadi Morwadi, Ajamera, Mohan Nagar, Yamuna Nagar, rupi Nagar, Talawade, Phule Nagar, Chikhali road, Shahu nagar

MAINTENANCE OF THE PLANT

A manufacturing unit like the one at the Katraj Dairy plant has many machines, electrical units, etc., that needs regular maintenance. Katraj Dairy has a fixed routine that covers all the maintenance-required units.

[ELECTRICAL MAINTENANCE DEPARTMENT]

Machinery- All machinery requires maintenance. The maintenance is determined on the number of hours that it has been operated. Based on this the wear and tear of the various machine parts can be estimated. The parts that

usually require the maximum maintenance are the rollers of the packaging units. The machines that come in contact with the milk are was washed with boiling hot water, then with a chemical, then with boiling hot water again and then washed with cold water. This process takes place everyday with the small holding tanks.

Storage Tanks- There are two types of storage tanks when it comes to maintenance, the big and the small. The big storage tanks are washed on weekly bases while the smaller ones are washed on a daily basis. The process involves, washing with boiling hot water, then by a chemical, then with boiling hot water again and then washing with cold water.

Electrical Department- The electric department is in charge of all the electrical lies that run through the entire plant. They usually have a simple job of just changing the parts that whether down or fuse. A major problem they face is rodents eating their underground wires, however, they now run the cables through G.I. pipes. The other equipment that usually burn out are the M.C.B.s, wires that fuse, motor pumps, etc.

[MAIN ELECTRICAL POWER HOUSE OF THE PLANT]

Refrigeration Unit- This unit is in charge of all the refrigeration of

all the products inside Katraj Dairy. It contains 6 compressors out of which only 2 operate at a time. Each pair of compressors operates not more than 6 hours at a time. When the demand for refrigeration increases, 4 compressors run at a time. Ammonia gas is used for refrigeration. If there is low pressure in the lines of the ammonia gas, Sulphur powder is added to the gas to help detect any leaks.

Pest Control- Rodents are a problem everywhere. To take care of

them crews of pest control are called every 1-month to spray pesticides to keep the plant rodent free and hygienic.

BOARD OF DIRECTORS

The boards of directors have the power of all the decisions that are to made, in regards to Katraj Dairy. The chairman of Katraj Dairy for the term between 2009- 2013 is Mr. Shri. Rambhau Sambha Tule.

Mr. Shri. Rambhau Sambha Tule. Chairman

CUSTOMER REVIEWS
It creams better and tastes a lot better than the others Anita Bhoslae Muska forms a lot more easily Ranjana Payguday The milk gives our tea a whole different flavor Deepa Mistri

CONCLUSION
From this report we can conclude that the set up is not a mediocre one, but in fact up to global standards. The plant is very hygienic and well maintained. The idea and implementation of the idea of unifying the farmers and helping them with their problems is nothing but noble. All the products that are produced are of immense quality and

standard, because of which their consumer demand is growing day by day. Thus analyzing this report, we can say that Katraj Dairy is definitely up to global standards and has the potential to be one of the leading giants in the dairy industry.