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UNIT - IV
AGRO-BASED INDUSTRY
(MILK PRODUCTS AND ITS PROCESSING)

CONTENT


1. Introduction
2. Importance of Processed Milk
3. Milk Quality Test
4. Processing of :
a). Butter
b). Curd
c). Paneer
d). Mattha
e). Cheese
5. Conclusion







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INTRODUCTION
Dairying in India, over the years, has witnessed a sea change from a largely unorganized
activity into a blooming organized industry. Dairying in India has traditionally been a small
holders enterprise. As demand for milk and milk product is increasing rapidly, milk producers
are adopting dairy farming on commercial scale to top the market opportunities.
The dairy industry plays an important role in our daily life. Milk and its products are important
human food, it is potable, easy to digest and highly nutritive. One of the important factors
affecting the total amount of milk produced is utilized is the demand for the various products. In
order to prepare such a diversity of products, many different processes have been developed by
the industry.
The present study was conducted on a dairy cooperative, Uttaranchal Cooperative Dairy
Federation Ltd. (UCDFL) from 20th March to 5
th
April 2014, which is an apex level state
federation of district milk cooperative unions in the state of Uttarakhand. Established in the year
1965, with its head office at Mangal Parao, Haldwani (Nainital) for the successful
implementation of the dairy programmes in the state, for the socio-economic upliftment of the
poor remote areas by providing them a milk market at reasonable price. UCDFL is also popularly
known as Aanchal dairy, located in Raipur road, Dehradun district, and the product branding
is Aanchal.
This study focused mainly on the
numerous types of milk products and
its processing of Aanchal dairy,
such as milk, buttermilk (Mattha),
butter, cheddar cheese, cottage
cheese (Paneer), curd (dahi), and
table butter. Each of these has been
designed to take advantage of some
particular property of milk. They are
usually high energy yielding food
products. The major protein in milk,
accounting for about 80% of the total
protein, is called casein.

WHY PROCESS MILK?
There are many reasons to process milk into dairy products, such as the following:
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Many dairy products can be kept longer than fresh milk; therefore the milk does not
have to be consumed immediately.
The demand for fresh milk may be limited, and there may be more interest in dairy
products.
If the daily amount of fresh milk for sale is limited, it may be more economical to
process the milk into less perishable products, store them, and sell them later in greater
quantities.
There may be no market for fresh milk close by, and only preserved products can be
sold at markets at a greater distance.
Greater financial gain may be obtained.

MILK AND its COMPOSITION
Milk is the primary source of nutrition for neonates before they start digesting other foods.
Although milk from several species such as cattle, buffalo, sheep, goat etc., has also studied
scientifically for several decades, cows milk has proven to have vast benefits to human health
and nutrition due to its resemblance to human milk composition (agastonia et al. 2000; lonnerdal
and Atkinson 1995).
The major constituent of milk is water, but according to species milk contains varying quantities
of lipids, proteins and carbohydrates which are synthesized within the mammary gland.

TABLE 23: MILK COMPOSITION ANALYSIS OF COW, PER 100 GRAMS

Constituents

Composition
Water 87.8 g
Protein 3.2 g
Fat 3.9 g
Carbohydrate(lactose) 4.8 g
Cholesterol 14 mg
Calcium 120 mg
Energy 66 kcal

Milk is a complex, nutritious product that contains more than 100 substances that are
either in solution, suspension or emulsion in water. For example, casein (major protein of milk),
the fat and fat soluble vitamins, lactose (milk sugar) and mineral salts. The casein micelles and
the fat globules give milk most of its physical characteristics, and give taste and flavor to dairy
products such as butter, cheese, yogurt, etc. the composition of milk varies considerably with the
breed of cow, stage of lactation, feed, season of the year, and many other factors.
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The composition of milk also varies with different breeds. The breeds have similar lactose level,
but milk fat and protein may vary considerably. These differences are partly genetic in origin and
partly the results of environmental and physiological factors.
1 PROCESSING OF MILK
"Milk processing" means the handling, preparing, packaging, or processing of milk in
any manner in preparation for sale as food. Milk processing does not include milking or
producing milk on a dairy farm that is shipped to a milk processing plant for further processing.
Milk can be stored longer if it has been processed. Extended storage is possible if you are able to
control the growth of micro-organisms. The processing technique used will determine the storage
life of the milk and dairy products. Some of the milk processing methods are:-
A. Standardization: Standardization is the process of increasing or decreasing a particular
constituent in milk or milk product so that it conforms to the desired industrial or legal
standards. Milk may be standardized to Full Cream Milk; Toned milk, Double Toned
Milk etc. Full Cream Milk should contain minimum 6.0% fat and 9.0% Solids Not Fat
(SNF) while Standardized Milk should contain minimum 4.5% Fat and 8.5% SNF.
Toned Milk and Double Toned Milk should contain minimum 3.0% Fat and 8.5% SNF
and minimum 1.5% Fat and 9.0% SNF, respectively.

B. Pasteurization: The microorganism that had gained entry into milk may be either
pathogenic (disease causing) or spoilage type. Pasteurization is the process of heating
milk just enough to kill harmful micro-organisms without destroying flavor and
nutritional qualities. Pasteurization may be done by two methods Low Temperature
Long Time (LTLT) or High Temperature Short Time (HTST). Nowadays, the HTST
method is mostly used. Milk is heated to either 63-65C for 20-30 minutes or 72-75C
for 15-30 seconds. Pasteurized milk has a shelf life of 2-3 days, and up to 12 days if kept
at 4C.

>Low pasteurization is used for milk for direct consumption and Cheese.
>High pasteurization is used for yoghurt, butter.


C. Cream Separation: In cream separation, fat is removed from the milk by passing it
through a cream separator in which it is rotated at a very high speed (around 8000
revolutions per minute) in thin films. Milk cream or fat, being lighter (specific gravity
0.9); remains in the centre while the skimmed milk, being heavier (specific gravity
1.036), goes towards the periphery in the cream separator. The separated cream and milk
are collected from different outlets provided in the cream separator.

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D. Homogenization: Homogenization breaks up the oil droplets in milk and prevents the
cream from separating out and forming a layer. This is of particular importance for
sterilized milk which has a long shelf-life and when the formation of a cream layer is not
desired. Additional changes include increased viscosity and a richer taste. Homogenizers
are more usually designed for industrial-scale production, but it is possible to purchase
smaller versions.
E. Sterilization: Sterilization is a more severe heat treatment designed to destroy all
contaminating bacteria. The milk is sterilized at a temperature of 121C maintained for
15-20 minutes or 150 degree C for 2-3 seconds so that a shelf life of six months of milk
at room temperature is ensured.
The pasteurization temperature to be used depends on the product to
be made of the milk.
F. Fermentation: Some desirable bacteria convert lactose of milk into lactic acid and
some other flavor-producing compounds and are helpful in producing different products
like dahi, yoghurt, etc. Conversion of milk into various cultured products by these
bacteria is known as fermentation and these products are known as fermented milk
products.

MILK QUALITY TEST
Milk testing for quality can be divided into testing for hygiene and for composition. The
milk testing equipments should always be cleaned thoroughly after use, for that we can use
boiling water for at least one minute, 70% alcohol or keeping the equipment in a flame.
Some methods of the test are given below:-

1. Taste, smell, visual observation and temperature:
This is always the first screening of the milk, since it is cheap, quick and does not
require any equipment. These tests are also called 'organoleptic tests'. It is also reliable if
the person carrying out the tests is experienced. The tester smells the milk, observes the
appearance, tastes if necessary, checks the can for cleanliness, looks for sediment, and
filters the milk to check its cleanliness. If doubts arise after the examination about the
quality of the milk, other tests can be done to determine the quality.
2. Density meter or lactometer test:
With a lactometer the specific density of milk is measured. At 15c the normal density of
the milk ranges from 1.028 to 1.033 g/ml, whereas water has a density of 1.0 g/ml. So
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when we read the lactometer, we can determine whether water has been added to the
milk. It is best to combine the lactometer reading with the fat test. We can use the
lactometer reading together with the fat percentage to estimate the Solids Non Fat (SNF)
content of the milk. Always read the temperature of the milk first, the lactometer reading
varies according to the temperature.
3. Acidity test:
This test measures the lactic acid in the milk. If the acidity is higher than 0.19%, then the
milk quality is poor and cannot be processed. If the acidity is lower than normal (e.g.
0.10% lactic acid) then the milk is of poor bacterial quality or sodium
hydroxide/bicarbonate might have been added.
For this test we need a white porcelain dish, a 10 ml pipette, a 1 ml pipette, a burette (0.1
ml graduations), a glass rod for stirring, a phenolphthalein indicator solution (0.5% in
50% alcohol) and a 0.1 N Sodium Hydroxide solution. Measure 9 ml of the milk into the
dish, add 1 ml of phenolphthalein and from the burette, slowly add the 0.1 N sodium
hydroxide solution while mixing continuously, until a faint pink color appears. The more
Sodium Hydroxide you have to add before it turns pink, the more acid the milk.
5. Gerber test for fat:
This test is used to determine the fat content of the milk. 10.94 ml. of milk at 20 degrees Celsius
is added to a butyrometer together with sulphuric acid and amyl alcohol. After centrifugation, the
sample is put in a 65 degrees Celsius water bath and read after 3 minutes. The fat content from
this reading should not be less than 3%.

Aanchal Dairy Milk
Products
A. Pasteurized
package liquid
milk:

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Milk is first received in a dump tank from the road milk tankers. It is then chilled to 4c. the
milk is then pasteurized and cream is separated to get skimmed milk. Milk is then standardized
depending on the requirement of toned milk, double toned milk, full cream milk or standard
milk. The pasteurized milk is sent
for packaging in pouches in the
packing machine for various
capacities like 500 or 1000 ml
pouches. Once packaged, the packet
milk is quickly conveyed to a cold
storage warehouse and later sent
out to the market for sale. The
products have sell-by-date printed
on the package.

TABLE 24: FAT % & SNF OF
VARIOUS FORMS OF MILK
Type
of
Milk
Quantity
of Milk
Fa
t
%

SNF(so
lid non-
fat) %

Full
cream
milk
500/1000
ml
6 9
Standa
rd
milk
500/1000
ml
4.
5
8.5
Toned
milk
500/1000
ml
3 8.5
Doubl
e
toned
milk
200/500/1
000 ml
1.
5
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1. Butter:
Butter is a fat concentrate which is obtained by churning cream. It is normally obtained from
cow's or buffalo's milk. First of all, cream or curd is obtained from the milk and then it is
converted into the butter. Butter contains about 80% fat by weight. Some time salt is added in the
butter for flavor and carotene as coloring matter.
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TABLE 25: THE COMPOSITION OF BUTTER.
Content %
Fat 80
Moisture 16.3
Curd 0.7
Salt 2.6

Flow chart of manufacturing butter:-
Separation of milk Separation of cream Neutralization of cream

Cream
Pasteurization of cream


Salt Colour


Cream ripening
Churning
Packaging
Cutting


Cold storage Marketing

2. Curd or Dahi:
Dahi, Indian curd is a fermented milk product obtained from pasteurized or boiled milk
by souring (natural or otherwise), suing a harmless lactic acid or other bacterial cultures. Dahi
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should have the same minimum percentage of fat and solid-not-fat (SNF) as the milk from which
it is prepared.
Manufacturing Process - Milk of cow is steamed for a minimum of 30 minutes and cooled to a
temperature of 43c and then incubated with 30% yoghurt starter. It is mixed thoroughly, filled
into the glass bottles and sealed with aluminium foil caps and kept it at 42c+0.5c for 3.5 hours
when the coagulum is formed. Then bottles are removed from water and placed into a water bath,
having temperature of 30c for 30 minutes and transferred to refrigerator for overnight storage.
Flow Chart of manufacturing curd:-
Cow milk

Filtration / clarification
Standardization (Fat: Solids not fat ratio)

Pre-heating (60)

Homogenization and pasteurization (80-90C for 15 to 30 min)

Cooling (22 25C)

Inoculation with pure lactic culture (single or mixed mesophilic culture)

Packaging

Incubation (23 25C for 16 to 18 h)

Cooling and storage at 5C

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3. Cottage cheese or Paneer:
Paneer is an acid-coagulated product of hot milk. It is marble white in appearance with a
slight spongy-body and close knit-texture. It offers outstanding non-melt functionality because of
its ability to withstand cooking and frying temperature. The Pure Food Act of India requires
Paneer to have not more than 70% moisture and not less than 50% fat on a dry matter basis.
Skim milk Paneer should not have more than 70% moisture and not more than 13% fat on a dry
matter basis.
Manufacturing of Paneer: - Paneer is obtained through heat or acid coagulation of casein
component of standardized milk, entrapping through various interactions almost all fat, part of
the denatured whey proteins, and colloidal salts as well as part of the soluble milk solids. The
typical composition of Paneer is 53-55% moisture, 23-26% fat, 17-18% protein, 2.0-2.5%
lactose, and 1.5-2.0% minerals.
Flow Chart of manufacturing Paneer:-
Fresh Cow Milk

Filtration

Standardization (Fat: SNF = 1: 1.65)

Addition of Calcium chloride (0.08 %)

Heated to 90
O
C (no hold)

Cooled to 85
O
C
Addition of Citric acid
Solution (1% at 85
O
C) Coagulation (pH 5.2-5.3)

Settling of coagulated mass for 5 min
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Whey drainage,

Filled into muslin cloth lined cylindrical hoop

Pressed (2-3 Kg/Cm2 for 10-15 min)

Immersed in chilled water


(4
O
C for 1-2 h)

Cut
into 100g circular (1.5 cm thick
and 10 cm diameter)

Experimental
sample
Control sample

Packaging

4. Mattha:
Mattha, also called chaanch is an Indian spiced beverage made of buttermilk. It is thin
and more acidic than conventional milk. Plain buttermilk is also called by Mattha. It is generally
mixed with mint, roasted cuming seeds, curry leaves. Salt and sugar for flavoring. The sourness
or tartness is due to the presence of lactic acid in the milk.

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6. Cheese:
Cheese is an economical source of milk protein. It provides a palatable milk product of high
value which can be kept for a long time. It is rich in calcium, vitamins and is nourishing and is
easily digestible food.
Manufacturing of cheese flow chart:-
Milk

Automated Standardization

Concentration (ultra filtration) (15% - 18% total solids)

Cheese making
(Enclosed Automated Vats)

Drainage conveyer (curd and whey separated)

Cheddaring tower

Salting

Block former


Packaging


Ripening (5c - 6c)
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CONCLUSION
Milk is a highly versatile, perishable raw material that can be manufactured into a wide
range of products. The processes that are used can be grouped as fractionation, concentration,
and preservation, this classification emphasizes the versatility of milk as a multicomponent raw
material, from which components can be selectively concentrated and stabilized.
The processes and products described are only a proportion of that in commercial use today or in
development. Sale of ghee, butter, yoghurt and other products have increased in the recent years.
Organic milk production has not only improved the economics of milk producers, but is also
providing employment to the rural people at the village level.
Milk processing is often more problematic than in temperate climates, owing to higher
temperatures and humidity. Consequently, milk spoils at a faster rate, cheese ripens too quickly,
and it is often difficult to ensure adequate cooling conditions. The extent of such changes and the
consequences for the properties and stability of milk depends on the severity of the treatment, as
well as the physiochemical changes that occur during processing.
The dairy industry can meet the needs of the consumers and expand the dairy product market by
undertaking new approaches to processing and product development. Control and optimization
of production processes are of great importance to the food industry as this may lead to
improvement of products and processes, and to cost savings. At present, Aanchal Dairy is
providing employment to rural people, eliminating any middle men. To maintain a continuous
growth in milk production, it requires the collective effort.
In conclusion, the processing of milk represents perhaps one of the most complex fields in the
food science and technology, and whiles many underpinning principles have been characterized,
and much research to be done in several areas. Furthermore, safety relevant issues to new
formulations and processing conditions for extended shelf-life products will continue to
challenge the food and dairy industries.