INTRODUCTION:

The Dharmapuri district co-operative milk producers union Ltd., The commercial
productions products are butter, ghee and skim milk powder started on 16.08.1983 with the help of
NDDB. Its main aim is to procure the milk .with good payment and to cater the needs of the metro
dairy‟s local demand and to convert the surplus milk into butter, ghee .In the earlier stages the
union has procured only a quantity of 33,000 litres of milk per day with its 227 primary milk
producers Co-operative societies. Then the union gradually developed its activities and reached a
daily average of 4, 51,371 litres per day (LPD). At initial state, the dairy was started functioning
with a handling capacity of 10,000 LPD, which was subsequently increased, to approximately
4,00,000 LPD. Unde SDCMPUL 3 chilling centers.
.The SDCMPUL is a pure Co-operative sector. It is worked grade name Aavin. Entire
dairy follows 3-tire system.

1.Primary milk producers Co-operative societies.

2 District union level.
3.Milk producer‟s federation ltd.

OBJECTIVE
1.Assure a remunerative price for the milk produced by the member of the milk
producer‟s Co-operative societies through a stable, steady and well organized market support.
2.Distribution of quality milk and milk products to the consumers at reasonable price.
3.Reducing private sector‟s monopoly activities.
VISION

1. Reducing the artificial demands of the milk and milk products.

2.Provide milk and milk products at lower cost.
3.Following quality policy.
4.Stand by the international markets.
MISSION
1.Established the producing sectors.
2.Developing the employee‟s skill
3.Increasing the profit of the company.
4.Using advanced technologies for manufacturing.
5.Tie up with international sectors.
6.Create employment opportunities to rural areas.

QUALITY POLICY
Significant investment has to be made in milk procurement, equipments, chilling
andrefrigeration facilities. Also, training has to be imparted to improve the quality to bring it upto
international standards.Salem Aavin.Is.supply milk and milk products and satisfaction of
customers by adopting best standards in a hygienic and safe environment with continual
improvement of quality with motivation, commitment and training of employees”.
Salem Aavin milk production Ltd was awarded.

MILKDEFINITION:
Milk is the physiological secretion of normally functioning mammary glands. Milk
may be defined as the whole, fresh, clean, lacteal secretions obtained by the complete milking of
one or more healthy milk animals .Milk is an emulsion of butter, Fat and water. In milk, the
continuous phase is water and aqueous phase is protein, lactose, minerals and traces of other
substances such as enzymes, vitamins, gases, etc.

PROCESSING OF MILK
Can milk (20-25˚C)

Chiller way (3˚C)

Raw milk (5 - 1, 00,000 L)
Pasteurization (72-75˚C for 5 sec)
Homogenization (Fat separation)
Separator process (78-80˚C)
Cream skim milk
Butter & ghee milk powder

Constituents
Major : water, Fate, protein, lactose, ash or mineral
Water .Minor : phosphor lipids, sterols, vitamins, enzymes, pigments etc.
True : milk Fat, casein, lactose.

Chemical composition of milk

Water : 87.0%
Fat : 4.0%
SNF : 8.0%
Casein : 2.8%
Albumin + globulin : 0.6%
Lactose : 4.7%
Milk ash : 0.7%
Citric acid etc : 0.2%
CAN WASHER:
Drip saver Soft water rinse

Washing soda (1%60˚C)

Hot water rinse (90˚C)

 Hot air sterilization (120˚C)

Can tilting device

MILK PASTEURIZATION:
Milk pasteurization consists of 4 sections. They are given below

1.Regeneration section.
2.Heating section.
3.Holding section.
4.Cooling section.
1. Regeneration section:
The chilled milk first enters the regeneration section and the temperature of the milk
raised to 40 ˚C. In this section the raw milk is being heated by the outgoing pasteurized milk.

2. Heating section:
Immediately after regeneration section the milk is sent to heating section where the
temperature is 72.4˚C. Then the milk is passed to holding section.

3. Holding section:
Milk enters into the holding section where the holding time is exactly 15 sec, which isfound
to be optimum. In modern practice, the milk is passed through a pipe and the flowis
arranged in such a way to achieve the correct temperature at 72˚C. Milk is then sent tothe
regeneration section where the temperature is reduced to 40˚C. Hence, milk is cooled
prior to cooling section.

4. Cooling section:
The milk is sent to cooling section where the temperature is gradually reduced from
24˚C and then finally the temperature is reduced to 5˚C.

REFRIGERATION

Alternative processing of condensation and evaporation called refrigeration.

Ammonia refrigeration is used for cooling the water. The low temperature and low pressure
ammonia vapor from the evaporator is passed to compressor. Inside the compressor, the ammonia
vapor is compressed to high pressure and temperature. In order to have a free movement of piston,
serve lubrication oil is used. Ammonia vapor reaches a high temperature
of 100˚C to 140˚C and high pressure of 180 pounds.
The ammonia vapor is then passed to condenser. In the condenser, the water is used
to cool the ammonia. During the cooling, ammonia vapor is cooled and changed to ammonia
liquid, which comes out from condenser.
Low temperature liquid ammonia is stored in receiver which is then pumped to
evaporator. In between tube, pressure is dropped with the help of flow diversion valve. So,180 PSI
is reduced to 30 PSI. During this time ammonia is cooled immediately to below 0˚C
and cooled ammonia is passed to evaporator. Hence, heat exchange takes place and water is
cooled to below 5˚C. In this dairy, there are three varieties of refrigeration unit namely 9×9,
7×7 and 5×5. Chilling the water up to 1˚C and for cooling the room upto 21˚C this unit is
used.
The low temperature and low pressure ammonia vapor is passed to compressor
andprocess is continued.

Compressor

* Reciprocating type (9×9)

*18˚C& 30 PSI pressure

* Discharge gas at 180PSI at 100˚C

* Oil separator (removal of oil from compressor)

*Boost compressor is used only for cooling room at .˚C

Condenser

* Evaporative type

* Water spraying and air blow system-

* Converting ammonia gas into liquid at pressure 180-175 PSI at normal temperature.

Expansion valve

* Main work is to reduce the high pressure suddenly

* Temperature decreases to ˚C

* Converting ammonia liquid to vapor

Over view:
Compressor capacity (6) : 70 ton

Condenser (7) : 75 ton

IBT (Ice Bank Tanks) : 50, 000 ltr (each)

Other 4 tanks : 45, 000 ltr

 Ammonia liquid compressor condenser30 PSI at normal room
(180 PSI at 100˚C)
Temperature liquid receiver Expansion valve Evaporator Refrigeration cycle in Aavin

BUTTER SECTION

Butter serves as the balance wheel of Salem dairy. The surplus milk is converted into
butter and a portion of it to ghee. Pasteurized cream at 8-12% from cream storage tanks are taken
for butter preparation, with the help of butter churn or continuous butter making machine. The
butter obtained is either used for conversion into ghee or for sales in 500gmpacks or 20 kg bulk
packs.

OPERATION OF BUTTER SECTION

The capacity of the chuen is around 5000 L. After proper cleaning with chlorine
water, the cream is pumped to 1/3 of the churn and closed. The chilled water, spray and the motor
is started. The churning occurs at 28 rpm, peaking at 8 rpm, and final stage at 15 rpm .The whole
operation of a batch takes around 1-2 hrs for completion. Table butter is prepared in the butter
churn only. Salt is added at the final working by sprinkling. If any color is added(not done now) it
is added to cream.

OPERATION OF CONTINUOUS BUTTER MAKING MACHINE (CBM)

The CBM comprises of 3 units that are arranged on top of each other. These are
the heater, the draining unit and the kneader. The cream is fed to the CBM through a screw
pump(for continuous air free flow). The cream enters the beater, where cream gets separated into
fine butter granules and butter milk .The butter rotates at 900-2200 rpm. Butter milk is drained off
and the granules are washed and worked in the separator with chilled water supply. The butter then
passes through a kneader (a twin screw conveyor) for the air-free flow of the butter. The Fat % of
the butter obtained from CBM is around 82-84% milk Fat. The quantity of butter depends on the
inlet temperatures and Fat content of the cream. For sweet cream, the optimum range of cram Fat
content is between 45 and 50 %. For sour it is between 38 and 42 %. The butter milk drained from
the butter churn and CBM is checked for Fat, SNF and acidity. If the acidity is normal, it is mixed
with the raw milk.

BUTTER PACKING MACHINE

The packing machine is of complicated mechanism working on a motor and a

vacuum pump. The butter to be packed is fed manually into the hopper, which has twin screw
conveyors into a mould on a rotating head, which helps in the continuous supply of butter. The
vacuum pump helps in parchment paper movement 500 g blocks are wrapping in parchment paper.
This is packed manually in cartons. Major portion of butter manufactured by CBM is used for
build packing ie. 20kg cooking butter in CFB cartons.
 BUTTER

Butter may be defined as Fat concentrate obtained by churning cream gathering the
Fat as a compact mass and then working it without the addition of common salt. It should be free
from other animal Fat and mineral oils.
Cream
Storage tanks (3 hrs at 10˚C)
Usage of butter churner Butter milk Butter Storage in tanks
Storage at 16˚C for ripening
Packaging and storage in -21˚C
Store in room temperature Grading Marketing Marketing

POWDER PLANT
krishnagiri dairy gas got a well equipped powder plant for the production of SMP.
The designed capacity of the plant is 10 T/day. But, the actual production capacity is 8 T/day. This
is due to less TS (8.4-8.6%). According to designed capacity if the SM has 9.4% TS, then the
output will be 10 T/day. Powder plant consists of 2 sections, an evaporating unit for concentrating
SM to TS level around 40-45% and a spray drying unit for converting the concentrated milk into
powder. Out of 4.5Lakhs liters of milk procured, about 60,000 L of pasteurized skim milk is used
for the manufacture of SMP. Powder plant has got 2 skim milk silos each having storage capacity
of 60,000 L.

FLOW CHART FOR EVAPORATOR PLANT

Skim milk (6˚C)

Barometric condenser (40-45˚C)

Regeneration at calendria III (48˚C)

Regeneration at calendria II (56˚C)

Regeneration at calendria I (68˚C)

Pasteurization (90˚C)

Holding section (15 sec)

Calendria I (68˚C, 17.52% cone)

Calendria II (56˚C, 44% cone)

 Calendria III (48˚C, 32.94% cone)

Condensed milk (40-45 % TS)

37
The evaporating unit is equipped with a falling triple effect evaporator to minimize
steam consumption. The SM from the silo is fed to the evaporation plant at a rate of 4800kg/hr
(due to less total solid content in skim milk), but the designed capacity is 5100 kg/hr. After
receiving the lab report, SM is pumped into the feed balance tank. From the FBT, the SM is
pumped to the condenser through coiled tubes where the SM at 6˚C is preheated to
around 40-45˚C by the vapor collected from the evaporator. Then, the SM at 45˚C
is passed through the calendria III, II, I respectively where in all these calendria, the incoming SM
is heated by the outgoing heated milk. Then the milk enters the pasteurizer and held at
pasteurization temperature (90˚C) for 15 sec.

After pasteurization, milk enters calendria I where vacuum is maintained at the

levelof 580 mm of Hg, hence boiling of milk occurs at 68˚C. The vapor and the milk enter vapor
separator, from their milk is pumped to calendria III, boiling occurs at 48˚C and a vacuum level
around 680 mm of Hg is maintained. Then that milk is pumped into calendria II where final
boiling occurs at 56˚C and vacuum level is 620 mm of Hg. Then, the concentrated milk is pumped
to the feed balance tank of the spray dryer. On the way to feed tank the concentration of milk is
analyzed by using Baume refracto meter. The condensed milk should have a Baume reading of 19-
22, which is correct concentration for spray drying process. In the case of lower Baume reading,
the milk is again sent to the evaporator through the balance tank. The vapor condensate from
condenser is mixed with water and it is pump spray pond for cooling. The cooled water is again re
circulated to the condenser.

38
EVAPORATOR DETAILS
No. of tubes in calendria I, II & III - 187,110,110 respectivelySteam pressure - 14kg/cmCalendria
IJacket temperature -
78˚C
Vapor separator temperature -
68˚C
Calendria IIVapor separator temperature -
56˚C
Calendria IIIVapor separator temperature -
48˚C
Condenser water inlet temperature -
30˚C
 Condenser water outlet temperature -
38˚C
Pasteurization temperature -
90˚C/cm
2
Steam pressure for t9hermo compressor - 14kg/cmMilk feed rate - 5100 kg/hrInitial total solid
content - 8.5%Final total solid concentrate - 40-43%Water evaporation - 4040 kg/hrConcentrate
output - 1000 kg/hrSteam consumption in tubular & pasteurizer - 1200kg/hrCondensate
temperatureCalendria I -
78˚C
Calendria II and III -
55˚C

39
PERFORMANCE DATA
Ambient temperature :
30˚C

Concentrated feed at 45˚C

: 1060 kg/ hrWater evaporation : 560 kg/ hrSolid concentration in the feed : 40-45 %Feed
temperature : 53-
55˚C
Inlet hot air temperature : 185-
190˚C
Outlet hot air temperature : 88-
90˚C
Powder moisture : 3.4 %Supply air quality : 17,000 kg/ hrConveying air quality : 4000 kg/
hrPressure drop under main cyclone : 130-150 mm WCPressure drop under product cyclone : 150-
175 mm WCChamber vaccum : 10 mm WCSteam consumption at 14 kg/ cm
2
: 1260 kg/ hrEnergy consumption : 112 KWHPowder production : 500 kg/ hrPowder temperature
at packing :
40˚C
Powder storage silos : 4*1000 kg

40
POWDER FILLING SECTION
The powder from the spray drier is filled into 25 kg bags. Then they are stitched in astichwell
machine. Stitching is done by pressing the pedal manually at the bottom of themachine. Capacity
of the filling section is 15 bags/ hr. After filling the powder in the 25 bagsthey are stored in
godown having capacity of 400T at the room temperature. Insecticides usedin godown are
malathene, Hit Beccan Spray for controlling Rats and insects.Arranging, 588 × 5 = 40 × 15 = 600
Bags.
CLEANING PROCEDURE
The CIP cleaning employed in the powder plant is as follows:Raw water : 15 mtsLye (1.5 % Na
2
CO
3
: 30 mtsHot water : 10 mtsAcid (HNO
3
, 1%) : 15 mtsLye : 5 mtsHot water : 15 mtsTotal : 90 mtsFor evaporator plant, either after 18-20
hrs of plant operation or 45000-90000 L of skim milk is taken for evaporation, the plant is cleaned
by CIP.

41
For spray drying plant, clean the entire feed system at the end of each run with causticsolution
(1.5%). Concentrate tank is also cleaned manually. The powder deposits on the wallscan be
collected by hammering. This procedure is followed after every run (20 hrs). Manualcleaning of
the drying chamber is carried out weekly once. The chamber door is opened andsuction fan is put
on. Then the entire sticking particles are swept off using a brush.

48 CHECKING FOR LEAKAGE IN TETRA PACKS

Mechanical package check Electrolytic package check Satisfactory Unsatisfactory Leakage

type Records

MECHANICAAAL PACKAGE CHECK

This is performed by pressing manually,
Checking of sealing :

Both longitudinal sealing (LS) and transverse sealing (TS)

TS : By tearing of sealing area and analyze

LS : Check the stip sealing by injecting dye solution2.

ELECTROLYTIC PACKAGE CHECK

This method is based on the electrolytic cell. If there is a leakage in the package or damage
to the inner plastic layer a current will flow through the circuit and ammeter gives the readings.
LEAKAGE TYPE INK TEST
The reagents used in this case are propanol which acts as a solvent and erythrosine
dye. Instead of erythrosine, Rhodamine 6 G solution can also be used. Mix about 2 gm of dye
solution with 1000 ml propanol. After shaking it is left over night and filtrate is usedfor the testing
(after evaporation). For testing carton is filled with water and it is wipedinside. Test ink is filled to
a level and sure that critical points are being covered. Removethe dye solution, dry completely by
using a dryer then it can be split and check for anydamage in the packet by ink penetration. In
order to check proper filling of packages every half an hour packages are weighed during
processing.

MARKETING SECTION & STORES

The Aavin, Salem has got a marketing section of its own. The main function of this section is to
supply various products/ milk to the consumers. Out of the 3.15 Lakhs litres of milk procured
around 1.6 Lakhs L of milk is send for local sales through milk marketing offices (MMO). About
1.2 producing various milk products.The various dairy products are distributed to various cities
through carry forward (CF)agents. Retailers also market milk products through the dairy own
parlors. Marketing Milk Products Type Channels Channels Varieties Toned milk Federation Ghee
Chennai metro At Chennai Butter MMO unitSTD milk SMP Dist unions High Fat milk UHT milk
C & F agents Khoa Whole salers Mysore pa Butter milk

PREPAC SECTION

Prepac section of Aavin, KRISHNAGIRI fills the pasteurizer chilled milk into pouches
and then sends it for local marketing through its 24 milk routes. The packing operations are done
twice daily-morning and evening.
Morning: 8.30 am-12.30 pm
Evening: 6.00 pm-2.00 am
In these section 11 double head prepac machines, 3 over head tanks and an outside silo,
crate washer, facility for CIP and cold room are available. For supply of compressed air,
compressors are also located (6 kg/cm) in a compressor room. For easy dispatch, dispatch section
is located at the other side of the packaging section.

Depending on the marketing interests, type of milk packed and volume can also be
varied. Milk usually packed is;

Standardized milk (4.5,8.5)

Toned milk (3.0,8.5)
STD milk packed in 500 ml and 250 ml pouches. Toned milk only 500 ml packet
ISI tubes use for carrying the milk sachets are return at one side of the section. After the
manual cleaning of the tubs, these are passed through a straight through crate washe rof capacity
850 tubs/ hr. The cleaned tubs are directly conveyed to the prepac region where filled packets are
arranged in it and send for dispatch. The volume of milk packed depends on the mark
requirement.
The processed milk from silos is collected in a vertical silo located outside the section.
From the silo, milk is pumped onto an overhead tank from where milk is taken to the milk is taken
to the tank on the top of the packaging machine (40 L capacity). The filling rolls are fed into the
packaging machine simultaneously. After proper sterilization of the film by UV radiation it passes
in such a way that the machine forms, fills and seals the packages. The sealing temperature and
filling quantities are adjusted.
The film used here are co-extruded PE films (50-55µ) which gives a yield of 8600
packets for 500 ml sachets filling per 20 kg roll. On an average, about 25-32 packets per head per
minute are produced. The weight of the milk sachets are tested every half anhour during packing.
The filled sachets are readily sent for dispatch with the help of 25milk distribution vehicles. CIP
cleaning is done after each batch packaging operations. Manual cleaning is done once in 3 days
interval. Acid cleaning is done once in 15 days.

61
PACKING SECTION (MILK)

LDPE- 20 kg in marching (bar side loading)

5˚C Feed inlet in the machine lead tank (40 L)

Operated – setting the volume of milk (250 ml (or) 500 ml)

LDPE– covering the vertical position

Sealing - vertical for temp low Herp (in slid)

Milk volume (Automatic filler)

Scauing – Horizontal and cutting (high temperature)

Manually filled the grade (check the leakage)

Despatch (or) stored

EFFLUENT TREATMENT PLANT

For waste water treatment an effluent treatment plant is maintained in the dairy. The waste will be
processing a high BOD which is to be reduced before draining for various purposes like irrigation.

Waste water
Screen chamber (big particles are sieved and scum being collected)
 Equalization tank (BOD is decreased by the supply of air)
Chemical dozer

Clari – floculator with agitator

Aeration tank

Final clarifier

Sludge is drained to sludge bed. The clear solution which overflows is stored and used for
irrigation. The ETP can handle 70000 LPD of waste water.

BOILER
(steam generating equipment)
(i)Water tube boiler (used only in power industry)
(ii)Fire tube boiler

Boiler type : IAEC (Indian Agri Engg co.opp)

Heating capacity : 11200165 / hr or 5 T/ hr

Horizontal packaged fire type : Three phase

Heating surface : 118m2

Burn flame type & Jeb type :65˚C

Designing pressure : 19.5 kg/ cm2

Working pressure : 16.5 kg/ cm2

Water type : soft waterFurnace oil flame point

Assembling parts in boiler:

*Blow down valve

*Main stop valve

*Feed check valve

 *Safety valve

*Air vent valve-

*Gauge glass-

*Pressure gauge

*Blower

*Feed pump

*Oil pre heater (85-70˚C)

CONCLUSION
SDCMPU place an inevitable role in tamilnadu milk producers federation Lts,
Chennai. Aavin krishnagiri has got ISO 9001-2000 certification. All the employees and employers
are unitedly working to achieve their goal. Their main aim is to improve the quality of milk and
milk products.

“Aavin”Salem being the first part of my in plant training programme helped me a lot.
It was really a good experience for me. It was guiding to me on the professional side. I hope that
this may help me a lot in my future carrier. I received kind co operation and all the help needed
from the dairy. I thank all for the same, wish them success in all their endeavors.

Thank you