DAIRY PROCESS OF MILK
MATERIALS REQUIRED FOR RAW MILK
REQUIREMENTS
1. BUFFALOES
2. GRASS
3. HUSK
4. JARS [ 100 ]
5. BUCKETS [ 100 ]
6. CANS
7. VEHICLES
8. MAN POWER [ 50 ]
RAW MILK PROCESS [ MILK BUSINESS REQUIREMENTS ]
1. WE NEED 1 TON OF GRASS QUANTITY FOR THE PERIOD OF ONE MONTH
2. WE NEED 100 BUFFALOES FOR GIVING MILK
3. WE NEED A SHED TO PROTECT THE BUFFALOES FROM WEATHER AND CLIMATIC CONDITIONS
4. EACH BUFFALO WILL EAT 10 KILOS PER MONTH
5. EACH BUFFALO WILL GIVE 6 - 7 LITRES OF MILK
6. WE NEED A SHED FOR STORING THE GRASS FOR BUFFALOES [ G1 – G10 ]
7. WE NEED A SHED OR SOME PLACE TO PROTECT THE MILK AND STORE THE MILK FROM WEATHER TEMPERATURE, OR CLIMATIC CONDITIONS
8. WE NEED A SHED TO TAKE REST AND FOR EATING THE FOOD FOR WORKERS
9. WE NEED ELECTRICITY TO MAINTAIN THE TEMPERATURE
10. WE NEED LOGS FOR PRODUCING ELECTRICITY IN CASE OF POWER FAILURE
11. WE NEED CANS FOR CARRYING THE MILK
12. WE NEED JARS TO MEASURE THE MILK
13. WE NEED HAND OPERATED PALLET TRUCK TO CARRYING THE CANS WITH IN THE RADIUS OF 2 ACRES OF LAND
14. WE NEED TO REQUIRED 10 VEHICLES FOR TRANSFER THE MILK
15. WE NEED TO REQUIRED 10 PERSONS OF MAN POWER FOR COLLECTING THE MILK
16. WE NEED TO REQUIRED 10 PERSONS OF MAN POWER FOR LAB TESTING PROCESS OF MILK
17. WE NEED 5 PERSONS OF MAN FOR TRANSFERRING THE MILK
18. EACH PERSON WILL COLLECTED THE GRASS WITH RESPECTIVE QUANTITY IN RESPECTIVE PLACES
19. EACH PERSON WILL COLLECT THE MILK FROM 10 BUFFALOES WITH THE HELP OF A BUCKETS
20. EACH PERSON WILL STORE THE MILK FOR THEIR RESPECTIVE LOCATIONS [ M1 – M 10 ] IN A SHED
21. TAKE THE 50 ML QUANTITY OF MILK FROM EACH BUCKET INTO EACH JAR
22. THEN TESTING THE MILK IN LAB
23. THEN CHECK THE FAT PERCENTAGE AND SNF PERCENTAGE FOR EACH BUFFALO AND NOTE THE FINDINGS
24. THEN ALL THE MILK WILL TRANSFER FROM BUCKETS TO STORAGE CONTAINER IN A SHED
25. AGAIN TEST THE MILK IN LAB
26. THEN CHECK AND STANDARDIZED THE FAT PERCENTAGE AND SNF PERCENTAGE FOR OVERALL MILK AND NOTE THE FINDINGS
27. THEN TRANSFER THE MILK FROM CONTAINER TO CANS WITH THE HELP OF A WORKER THROUGH THE JARS
28. THEN TRANSFER THE CANS KEPT INTO HAND OPERATED PALLET TRUCK WITH THE HELP OF A WORKER
29. THEN TRANSFERRED THE MILK CANS INTO VEHICLE THROUGH THE HELP A HAND OPERATING PALLET TRUCK
30. THEN ORGANISING THE MILK CANS IN A VEHICLE
31. THEN TRANSFER THE MILK CANS FROM MILK SHEDS TO MILK CENTER
32. THEN RECEIVED THE MILK FROM DIFFERENT MILK SHEDS FROM THE PRICE OF 10 RUPEES PER LITRE IN MILK CENTER
33. THEN TEST THE MILK FOR EACH MILK SHED THEN CHECK THE FAT PERCENTAGE AND SNF PERCENTAGE FOR EACH MILK SHED AND NOTE THE FINDINGS
34. THEN ALL THE MILK WILL TRANSFERRED FROM MILK INTO A STORAGE CONTAINER
35. AGAIN TEST THE MILK IN LAB
36. WE WILL CHECK AND STANDARDIZED THE MILK FAT PERCENTAGE AND SNF PERCENTAGE FOR OVERALL MILK AND NOTE THE FINDINGS
37. THEN TRANSFER MILK FROM MILK CENTERS TO MILK TANKERS WITH THE HELP OF INSULATED PIPELINE SYSTEM
38. THEN TRANSFER MILK FROM MILK CENTER TO MILK DAIRY THROUGH THE HELP OF MILK TANKER
39. THEN CHECK THE SEAL OF TANKER WHEN THE VEHICLE IS ARRIVED AT A DAIRY PLANT
40. THEN RECORD THE VEHICLE NUMBER AND TAKE A VEHICLE PHOTO/IMAGE
41. THEN RECEIVE ALL THE REPORTS [ VENDOR, MILK TANKER, MILK REPORTS ]
42. THEN CHECK THE GROSS QUATITY OF MILK TANKER THROUGH THE HELP OF WEIGH BRIDGE IN THE PRESENCE OF SECURITY PERSON
43. THEN RECORD THE GROSS QUANTITY OF A MILK TANKER
44. THEN SUBMIT THE LAB REPORT TO LAB ASSISTANT THROUGH FAX / HARD COPY
45. THEN CHECK THE TEMPERATURE OF MILK
46. IF MILK TANKERS HAS MULTIPLE COMPARTMENTS THEN TAKE THE SAMPLE MILK FROM EACH COMPARTMENT
47. THEN MILK TANKER WILL SEND TO DOCK YARD [ UNLOADING AREA ]
48. THEN UNLOADING THE FIRST COMPARTMENT OF MILK TANKER INTO FRESH SILO - 1
49. THEN RECORD THE GROSS QUANTITY OF MILK TANKER
50. THEN RECORD THE FINDINGS [ PREVIOUS GROSS QUANTITY – PRESENT GROSS QUANTITY OF MILK TANKER ]
51. THEN AGAIN MILK TANKER WILL SEND TO DOCK YARD [ UNLOADING AREA ]
52. THEN UNLOADING THE SECOND COMPARTMENT OF MILK TANKER INTO FRESH SILO - 2
53. THEN RECORD THE GROSS QUANTITY OF MILK TANKER
54. THEN RECORD THE FINDINGS [ PREVIOUS GROSS QUANTITY – PRESENT GROSS QUANTITY OF MILK TANKER ]
55. THEN AGAIN MILK TANKER WILL SEND TO DOCK YARD [ UNLOADING AREA ]
56. THEN UNLOADING THE THIRD COMPARTMENT OF MILK TANKER INTO FRESH SILO - 3
57. THEN RECORD THE GROSS QUANTITY OF MILK TANKER
58. THEN RECORD THE FINDINGS [ PREVIOUS GROSS QUANTITY – PRESENT GROSS QUANTITY OF MILK TANKER ]
59. THEN NOTE THE RECORDINGS OF MILK TANKER FOR EACH COMPARTMENT [ GROSS WEIGHT – NET WEIGHT = MILK QUANTITY ]
60. THEN MILK TANKER WILL RETURNS
MILK ANALYSIS PROCESS
WE WILL RECEIVE THE MILK FROM MILK TANKER AT 4℃ THROUGH INSULATED PIPELINE SYSTEM THEN TRANSFER MILK TO FILTRATION → COOLING → HEATING → SEPERATION → STANDARDIZATION → PASTEURIZATION → SILOS
1. PRECOOLING IS USED FOR PRVENTING BACTERIAL GROWTH
2. FILTRATION & CLAFICATION IS USED FOR REMOVING TINY PARTICLES DIRT AND CENTRIFUGAL CLARIFICATION
3. STANDARDIZATION IS USED FOR ADJUSTING THE SNF AND FAT LEVELS TO MEET PRODUCT SPECIFICATIONS
4. HOMOGENIZATION IS USED FOR BREAKDOWN THE FAT GLOBULES AND IMPROVE THE TEXTURE AND TASTE
5. PASTEURIZATION IS USED FOR DESTROYING HARMFUL BACTERIA
6. COOLING MILK SHOULD BE COOLING 4℃ AGAIN THEN STORED IN STORAGE TANKS
7. PACKING THE STORED MILK SHOULD BE READY FOR PACKING IN POUCHES THEN LABELING AND CODING
8. STORAGE THE MILK WILL BE STORAGE IN A COLD ROOM AT THE TEMPARATURE 4℃
9. DISTRIBUTION THE MILK SHOULD BE TRANSFERRED THROUGH COLD VEHICLES AT A TEMPERATURE OF 4℃ THEN DELIVERY TO B2C OR B2B CUSTOMERS
TYPES OF FINISHED PRODUCTS
1. FULL CREAM MILK 1000 ML
2. FULL CREAM MILK 475 ML
3. STANDARDIZED MILK 1000 ML
4. STANDARDIZED MILK 500 ML
5. TEA SPL 500 ML
6. TEA SPL 130 ML
7. DOUBLE TONED MILK 500 ML
8. TONED MILK 1000 ML
9. TONED MILK 500 ML
10. TONED MILK 140 ML
11. MAHA GOLD PLUS 475 ML
PACKING PROCESS
RAW MATERIALS FOR PACKING
THERE ARE THREE TYPES OF RAW MATERIALS FOR PACKING
1. KG ROLES
2. HALF KILO ROLES
3. 200 GRAMS ROLES
ONE KILO FILM ROLE IS USED FOR 240 LITRE MILK PACKETS
ONE HALF KILO FILM ROLE IS USED FOR 360 HALF LITRE MILK PACKETS
ONE SMALL FILM ROLE IS USED FOR 700 [200 ML] MILK PACKETS
MILK PACKET SEALING PROCESS
WE NEED A 18℃ TEMPERATURE FOR VERTICAL SEALING OF A MILK PACKET
WE NEED A 35℃ TEMPERATURE FOR HORIZONTAL SEALING OF A MILK PACKET
BI PRODUCTS MAKING PROCESS
TYPES OF BI PRODUCTS
1. BADAM MILK
2. PANEER
3. COVAKLOVA
4. DOODPEDA
BADAM MILK PROCESS
REQUIREMENTS
WE NEED DOUBLE TONED MILK WITH
FAT – 1.5%
SOLID NOT FAT – 10%
FOR BATCH PREPARATION WE NEED 120 LITRES OF DOUBLE TONED MILK
1. ADD BADAM MIX FLAVOUR 18 ML – 0.16%
2. ADD 15 GRAMS OF LEMON YELLOW COLOR
3. ADD 1 KG OF “M31” SUGAR OR 9.2% OF SUGAR
4. ADD COLORS 0.3%
5. ALL MIX IN BALANCE TANK
6. FILLING 200 ML MILK BOTTLE THROUGH INSULATED PIPELINE SYSTEM
7. THEN KEEP 30 MILK BOTTLES IN EACH CASE
8. THEN KEEP 30 CASES IN STERLIZER MACHINE
9. THEN MAINTAIN 120℃ TEMPERATURE
10. HOLDING FOR UPTO 15 MINUTES
11. THEN REMOVE THE CASES IN STERLIZER AND MAINTAIN AT ROOM TEMPERATURE FOR UPTO 48 HOURS
12. THEN DISPATCH THE FINAL PRODUCT
PANEER MAKING PROCESS
REQUIREMENTS
TAKE DOUBLE TONED PASTEURIZED MILK WITH FAT 4.5% AND THE SNF 8.2% - 8.8%
1. TAKE 90℃ PASTEURIZED MILK THEN HOLDING 15 MINUTES
2. THEN MAINTAIN 85℃ CELCIUS
3. THEN ADD COAGALINE 0.35%
4. WAIT FOR UPTO 10 MINUTES
5. THEN STRAIN THE WATER WITH MASCULINE CLOTH
6. THEN TRANSFER TO HOOPS
7. THEN APPLY 6 KG PRESSURE FOR 15 MINUTES
8. THEN TRANSFER TO CHILLED WATER 4 CELCIUS FOR UPTO 2 HOURS
9. THEN CUTTING AND SEALING
10. THEN SEALING THE PANEER WITH A CERTAIN WITH CERTAIN TEMPERATURE
11. THEN SET THE TIME FOR 5 MINUTES ON PACKING MACHINE
12. THEN TRANSFER THE COLD ROOM FOR MINIMUM 12 HOURS
COVA PICA CKOVA MAKING PROCESS
REQUIREMENTS
BUFFALO RAW MILK OR PASTEURIZED MILK
PROCESS
1. TAKE 80 LITRES OF BUFFALO RAW MILK OR PASTEURIZED MILK
2. THEN COVA PAN THEN POUR MILK INTO COVA PAN
3. MAINTAIN 2 KGS PRESSURE & STIRRING WELL FREQUENTLY WITH [SPOON] UPTO 2 HOURS
4. TIME TAKEN FOR 2 HOURS
5. THEN TRANSFER TO SS PLATES
6. MAINTAIN 30 MINUTES IN ROOM TEMPERATURE FOR COOLING
7. THEN PACKING THE FINISHED PRODUCT
DOODPEDA MAKING PROCESS
REQUIREMENTS
BUFFALO RAW MILK OR PASTEURIZED MILK
PROCESS
1. TAKE 80 LITRES OF BUFFALO RAW MILK OR PASTEURIZED MILK
2. THEN COVA PAN THEN POUR MIIK INTO COVA PAN
3. ADD SUGAR 8% IN COVA PAN AFTER POURING MILK INTO COVA PAN
4. MAINTAIN 2 KGS PRESSURE & STIRRING WELL FREQUENTLY WITH SPOON UPTO 2 HOURS
5. TIME TAKEN FOR 2 HOURS
6. THEN TRANSFER TO SS PLATES
7. MAINTAIN 30 MINUTES IN ROOM TEMPERATURE FOR COOLING
8. THEN PACKING THE FINAL FINISHED PRODUCT
BATCH 2 PANEER PRODUCTION
MILK QUANTITY - 300 LITRES
GDL - 1000 GRAMS
1 KG - 27+6=33 GRAMS
500 GRAMS - 0
200 GRAMS - 9+6=15
WASTAGE - 6KG
TOTAL PANEER QUANTITY - 42 KGS
PANEER PRODUCTION
MILK QUANTITY - 500 LITRES
GDL - 1700 GRAMS
1KG - 57
500 GRAMS - 2+5
200 GRAMS - 10+5
WASTAGE - 4 KG
TOTAL PANEER QUANTITY - 64 KG 500 GRAMS
SFM BADAM PRODUCTION BATCH – 1
MILK QUANTITY - 120 LITRES
SUGAR - 10 KGS
BADAM MIX - 1.5 KGS
BADAM FLAVOUR - 20 ML
LEMON YELLOW LIQUID - 20 GRAMS
LEMON YELLOW FOOD COLOR - 15 GRAMS
BOTTLE’S - 570 BOTTLE’S
DAMAGE BOTTLE’S - 30 BOTTLE’S
STERLIZER ON TIME - 3 : 26 PM
HOLDING TIME - 3 : 50 PM TO 4 : 03 PM
STEAM RELEASE TIME - 4 : 04 PM
STERLIZER DOOR OPEN TIME - 5 : 00 PM
MALAI LADDU
TAKE 1.5 KG SUGAR POWDER
ADD 1.5 KG GRAMS OF GHEE
ADD 1 KG MAIDA
ADD 1 KG SMP
ADD FRIED CASHEW’S 400 – 500 GRAMS
PREPARE A CIRCLE SHAPE – 25 GRAMS
VEILD – 4.5 KGS
