SALEM DISTRICT CO-OPERATIVE MILK

PRODUCERS’ UNION LIMITED

INTERNSHIP PROGRAMME REPORT

28.11.2019 - 7.12.2019

SUBMITTED BY
SASI REKHA K R
VIVEKANANDHA ARTS AND SCIENCE COLLEGE FOR
WOMEN
SANKARI
 SALEM DISTRICT CO-OPERATIVE MILK
PRODUCERS’ UNION LIMITED

INTERNSHIP PROGRAMME REPORT

28.11.2019 -7.12.2019

SUBMITTED BY
MAHALAKSHMI R
VIVEKANANDHA ARTS AND SCIENCE COLLEGE FOR
WOMEN
SANKARI
 SYNOPSIS

 Introduction
 Milk
 Overview of milk production
 Types of milk
 milk processing
 Cream production
 Ghee section
 Buttermilk production
 Curd section
 Aseptic packaging section (APS)
 Powder plant
 Water plant
 Refrigeration unit
 Effluent treatment plant (ETP)
 Sweet section
 Quality control department
 INTRODUCTION
Tamil Nadu Co-operative Milk Producers Federation
(TNCMPF) was formed in February 1981as an apex body
of three tire cooperatives setup in Tamil Nadu and the
District level milk producer unions were formed in the
year 1982.
Aavin is the trademark of Tamil Nadu Co-operative Milk
Producers’ Federation Limited. A Tamil Nadu based milk
producers’ union. Aavin procures milk, processes it and
sells milk and milk products to consumers.
To achieve the benefits of the “ Second White
Revolution”, TCMPF has taken various measures such as
payment of attractive procurement price to milkproducers
, huge investment in dairy infrastructure at all levels
starting from Primary Dairy Co-operative Societies, to
State Level Federation.

MILK
Milk is a nutrient-rich, white liquid food produced by the
Mammary glands of mammals. It is the primary source of
Nutritions for infant mammals (including humans who are
breastfed) before they are able to digest other types of
food.
Early lactation milk contains colostrum which
carriesthe the mothers antibodies to its young and can
reduce the risk of many disease.
Milk provides a favorable environment for the growth
of microorganisms. Yeast, Moulds and broad spectrum of
bacteria can growing milk.
Standard milk contains 4.5% of fat and full cream
milk contains 6.0% of fat.
As an agricultural product, milk also called dairy milk
, is extracted from farm animals during or soon after
pregnancy.
Dairy farms produced about 730 million tones of milk
in 2011, from 260 million dairy cows. India world ‘s
largest producer of milk, and is the leading exporter of
skimmed milk powder, yet it exports few other milk
products.
 OVERVIEW OF MILK PRODUCTION

Initially, the value of fat and SNF of raw milk would of 42

and 82. After processing, it will be 45 and 85.
 TYPES OF MILK

There are 4 types of milk are being manufactured here,

namely
 Full cream milk
 Standardized milk
 Tonned milk
 Skimmed milk

The fat and SNF value of the milk are in the following
lines:
o Standardized milk = 45 ,85
o Full cream milk = 60 , 90
o Skimmed/ tonned milk = 30 , 80
 MILK PROCESSING

 FULL CREAM MILK

Raw milk

Pasteurization

Homogenizer

Cooling

Add cream and powder

 STANDARD MILK

Raw milk

Pasteurization
 Homogenizer

Cooling

Silo

Standarised milk

 TONNED MILK
Raw milk

Pasteurization
Adding water & milk powder

Tonned milk

CREAM PRODUCTION
 RAW MILK

PASTEURIZATION

CREAM
SEPARATION

GHEE SECTION
 Full cream milk

Butter buttermilk

Boiling outlet

S1 & S2 tank

Cooling (1 hr)
Raw water
Pumping

Packing

Butter is separated from full cream milk and allowed to

boil in S1 and S2 tank for 2 hours. Ghee is cooled for an
hour by passing raw water over the tank and pumped out
for packing.
BUTTERMILK PRODUCTION

Standardized milk (STD milk)

Pasteurization (90oC)

Cooling (43oC)

Add inoculums

Curd preparation

Add chill water + masala

Blending

Butter milk
Butter milk is prepared from STD milk. Initially, curd is
prepared and mixed with chilled water and masala.
Altogether blended and packed.

CURD SECTION
Curd is prepared by 2 methods using STD milk.
Method (i)
Raw milk Pasteurization Cooling
(STD milk)
Add inoculums

Packaging cooling blending

Method (ii)
Raw milk Pasteurization Add inoculum

Packaging Cooling blending

 ASEPTIC PACKAGING SECTION
In APS, two products are manufacturing namely milk
shake and homogenized milk. these products are
exported.

 Milk shake
Two types:
 Flavoured milk shake
 Natural milk shake

Flavoured milk Natural milk shake

shake • Vanilla
• Strawberry • Chocolate
• Pista • Carrot
• Cardamon • Apple
• Mango
• Badam
Preparation of milk shake
Standardized milk

Flavor/ juice preparation (8C)

UHT treatment (137C)

Tetrapack package (25C)

STD milk is taken for manufacturing milk shake. Milk is

pasteurized and cooled at 8C simultaneously flaour/ juice
is extracted. Both are mixed and undergo UHT at 137C.
Milk shake will be packed using tetra pack (6 layers) at
25C.
Validity = 6 months.

Homogenized milk
This milk mainly manufactured for exporting to various
countries and states.
Preparation of homogenizer milk
Raw milk

Pasteurization

Homogenizer

UHT (137C)

1 liter machine (simple 8)

Cap applicator (by-pass mode)

Validity =180 days.

In an hour, 1 liter machine will manufacture 6000 packs.
This milk mainly exported to Singapore, Malaysia and
Japan.
 POWDER PLANT
Silo

Raw milk

Pasteurization

Cream separated

Flash method (100C)

Powder

WATER PLANT
The purpose of the water plant is for softening the water.
To remove the hardness from the normal water. Normal
water contains 120- 180ppm hardness. After undergoing
this treatment, hardness of the water will become 4-10
ppm
Two types of water being used, namely
 Softening water
 Demineralized water
Soft water
It consists of 3 process:
 Multi grand filter
 Activate carbon filter
 Resin (heart of the plant)
Resin helps in separating the salts from the water that
results in soft water.
200kg of NaCl+ 1000l H2O passes in inlets.
It reduces the ppm to 4-10 within 24 hours. The purpose
of this water is for cleaning.
Demineralized water
It also consists of 3 steps:
 Multi grand filter
 Activate carbon filter
 2 resins
It removes all the minerals in the water.
 REFRIGERATION UNIT

Temperature of the deep freezer would be -20C. It is one

of the preservation techniques. It helps in inactivating
microbial growth, only cryophilic microbes can able to
survive in this temperature

EFFLUENT TREATMENT PLANT (ETP)

It is the treatment which helps in recycling and reuse of
industrial waste water.
It recycled water is used for gardening. It also helps in
safe disposal to environment.
Following steps are done by ETP
Bar screen
(Removal of large objects)

Sump
(prevents blockages & eliminate foul odours)

Fat removal unit

(removal of fats)

Storage tank
(Storage)

Equalization tank
 Flashmisser
(neutrilization)

Holding tank

Buffer tank
(neutrilization)

UASB digester (Up-flow anaerobic

sludge blanket production)
(methane production)

Aeration
(activated sludge process)

Clarifier
(Removal of solid particles from liquid)

Collection tank
(PSF &ACF)

Treated water sludge

 SWEET SECTION
Many milk sweets are being manufactured in this
company. Sweets like halwa, ladoo and mixture will be
prepared only at the time of diwali.
Sweets that are prepared here are in the following lines.
 Milk khoa
 Mysorepak
 Milk cake
 Carrot mysorepak
 Kesari mysorepak
 Special mysorepak
 Soanpappudi
 Badam mix powder

Milk khoa and its preparation

Raw milk pasteurization homogenization

Condensation Add sugar add ghee

Allow it to cool packing

For a batch around 300Kg of mikkova will be prepared. It
consumes about 120L of milk and 12Kg of sugar. The
temperature here prevails will be around 40-60C.

Kesari pak (cashew cake)

Preparation of kesaripak:
Cashew nut grind it finely add sugar

Package Allow it cool fry in ghee

QUALITY CONTROL DEPARTMENT

This department is to check the quality of milk and milk
products using testing’s. Tests are performed in the
laboratory as follows:
 Milkoscan
 Organoleptic test
 Clot in boiling test
 Acidity test
 MBR test
 Lactometer test
 Other tests
 Khoa test
 Alfatoxin test
 Microbial test
 Coliform test
 Standard plate count
 Yeast and mould count

Milkoscan
This equipment is used to determine quantity of the fats,
non fats solid (SNF), proteins, lactose and water in the
given samples. Samples can be taken as fresh milk.
Organoleptic test
It rapidly analysis the poor quality of the milk. Milk
grader is required to have good sense of sight, smell and
taste. The primary observation is to check the smell,
appearance of the milk immediately after collection. Also
need to check the lid whether it is cleaned or not.

Clot on blotting test

COB is quick and easy test. In this test, if the samples
show negative results it means sample contains acid
producing bacteria or acid production or abnormal level
of proteins.
Such milk will turn into curd on heat treatment during
milk processing so such milk can be rejected.

Acidity test
Milk is a good media since it constitute all nutrients.
Bacteria normally grow in milk leads to lactose
fermentation and produce lactic acid as the byproduct.
 In this acidity test, lactic acid is neutralized with 0.1- 1N
solution of sodium hydroxide. From this amount of
sodium hydroxide can be determined through this
percentage of lactic acid can be calculated.

Methylene Blue Reduction test

Methylene blue is a blue colored dye. It is an indicator for
this test. The metabolites that are produced by the bacteria
will change the blue color to clear white. Rate of
reduction is directly proportional to the bacterial load in
the milk.
Sample collection(10ml)

Methylene blue solution(1ml)

Mix well

Placed it water bath @37C

 Note the decoloration time

 Instant color changes : Very poor quality

 5 hours or above: Very good quality

Lactometer test
Lactometer is a glass instrument used to check the purity
of the milk based on buoyancy or density. It works under
the principle of specific gravity.
 Density below 30: More water content
 Density above 30: Viscous milk

Other test
Khoa test
Silica gel is used to detect the khoa moisture.
Glass rod is used for mixing.
W3-W2
Moisture =________* 100
W2-W1
 Aflatoxin test
Aflatoxin is a secondary metabolite produced by
fungi, mainly Aspergilus flavus and Aspergilus
parasiticus. The major metabolites of aflatoxins are
B1 and B2.
Thin layer chromatography is used for this test.
It is an instant method. Raw milk is used as sample.

Microbial tests
Coliform count

Presence of coliform indicates the fecal

contamination.
 Agar : VRB agar
 Incubation time: 24 hrs
 Dilution factor
o Raw milk: 4th
o Powder, skim milk, butter milk, curd, cream: 1st
To detect the coliform in water macConkey broth is
used. To check the gas/acid production Durhams tube
is used and color chnges can be seen.
 Standard plate count

It is sensitive , accurate and reliable technique to

determine the bacterial colonies in the milk.
 Agar : Plate count agar
 Incubation time: 48 hrs
 Dilution factor
o Raw milk: 5th
o Powder : 2nd
o Cream, butter, curd, skim milk: 3rd

Yeast and mould count

 Agar : Potato dextrose agar (PDA)

 Incubation time : 3 days
 Dilution factor
o Butter milk, curd, cream butter: 1st