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ANAND MILK UNION LIMITED

A Project Report on :
Short term training

@ Kaira District Co-operative Milk producers Union Ltd. , Anand .


Training Period : Starting From 22/12/08 to 2/01/09
Shift Time
: 12:30pm to 4:30pm
Prepaid By :
Ronak Thakkar
Jaymin Zala
3rd Year students of B.E.(FPT) , ADIT , New V.V.Nagar.

Anand Pattern
STATE FEDERATION
Marketing

Money

PRODUCTS
DISTRICT UNION

Milk Procurement & Manufauring of Dairy Products


&
Technical Inputs and Co-operative Development
Programmes to Farmers

Money

AI

AH

MILK

FEED

EDU

PRIMARY VILLAGE CO-OPERATIVE SOCIETIES


Milk Production and Pooling through farmer producers

Introduction
For a milk farmer, whose life and livelihood is in our
rural hinterland, Amul is, Amul does!
This is the crux of the Amul brand and stems from the
support and ownership by over two million milk
producers of Gujarat
For the Consumer, Amul simply means 'Value For
Money' and Quality as it should be.
Amul makes each bite that much more special because in
our humble way, we care for feelings that are truly
"Indian".

HISTORY
In the year 1946 (14th December 1946) the first milk union
was established. This union was started with 250 liters of milk
per day. In the year 1955 AMUL was established. In the year
1946 the union was known as KAIRA DISTRICT COOPERATIVE MILK PRODUCERS UNION.
The brand name Amul means AMULYA.
Amul which inspired 'Operation Flood' and heralded the
'White Revolution' in India.
http://www.amul.com/. Is India's first national cyberstore,
functioning in some 120 cities, and an Amul Cyberstore
Gifting Service capable of serving consumers in more than
220 of our cities, on specific occasions. This has been made
possible by creating an IT network.

Amul-2 RMRD
This is very first department of any dairy where truck (cans) loaded
with milk are unloaded and simultaneously the milk is tested and
processed further in other departments. The RMRD at AMUL 2
received cow milk and buffalo milk in separate cans.
Even today around 60% of mandadis (600) send milk to the amul
dairy by cans each can have capacity of 65lit. Regular 33truks arrive
here in morning. Milk is taken in B.T. & by pump it is forwarded to
the pasteurizer.

Equipments :
1. Pasteurized milk storage tanke - 10 no. - 35729lits.
each - 16ft. deep
2. pasteurizer - 3 no.
Capacity P1 = 17000 liters , P2 = 7500 liters ,P3 =
12000 liters
3. separator - 2no.s & speed 4600rpm
4.Butter milk tanks 5no.s
5.Can Washer 2no.s
6.Weighing balance tank Capacity 500 kgs
& Collection tank
Capacity 2000 liters
7.Butter milk heating equipment (New arrived , IDMC)

Milk Pouch Packaging


Here Packaging of milk ,buter milk ,dahi is done. In different
sizes 200ml,500ml & 1lit.(T-special).
* Made by : pre pac , pamar pan , set pac
Pouches are the most popular, convenient and accepted
packaging for marketing of liquid milk. The Packaging Film
Project (PFP) was established to give a competitive edge to the
Co-operative Dairy, by ensuring access to the best quality food
grade packaging pouch film, for high speed pouch filling
machines, that operate at speeds 75 per cent higher than at
present.
* Packaging Film Project, Gandhinagar.
U.V. light is used to protect pouches from bacteria.
speed selector is used for 200,500,1000ml pouches.
Horizontal & vertical sealing injection. on/off
Impression coder is (of printech India) is used for marking
Mfg. date & Batch no.
Valve control penal : from which we can select inlet tank(silo)
& line. , for different products.

Flavor Section
Now a days amul is manufacturing of 14 types. 6
in bottles & 8 in tins. Namely : KOOL caf , coco
, kesar , nutramul , rose , elaichi , Milk sek badam ,
banana , strabery , mango.
The plant have capacity to manufacture 1lac. Tins &
1lac. Bottles per day.
coming soon is whey milk in coco flavor. (in next 6
months). We are try to make this in R&D
laboratory(central lab) .

Process Flow chart


Sugar hopper
Sugar conveyor

Provat
Homogenizer
Coffee blender
Bulk cooler
Packaging
Sterilizer
Cooling
Printing
Cartoon packaging

Slury tank

Amul 3 Reception & process


quality is prevention of wrong things
Purpose : To ensure that the process of milk reception ,
processing & issue or dispatch as per documented procedure.

Process Flow diagram

Source: Internet

Name of EQUIPMENT

Capacity

Number

Raw Milk Silo

1,50,000 Liters

Milk Clarifier

30,000 Liters

3 (Rpm 1400 to 1500)

Raw Milk Buffer tank

15000 Liters

Milk Pasteurizer

30,000 Liters / hour

2 (PHE-type)

Cream Separator

30,000 Liters

Cream Ripening Silos

40,000 Liters

Cream Buffer Tank

40,000 Liters

Cream Pasteurizer

10,000 Liters per hour

1 (PHE-type)

Balance Tank

350 Liters

Pasteurized milk silo

1,50,000 Liters

Butter milk storage tanks

40,000 Liters

CIP tanks for tankers

Water tank 8000 Liter Capacity


Lye tank 8000 Liters Capacity

1 each

CIP tanks

Lye tanks Capacity 10,000 Liters


Acid tank 10,000 Liters
Water tank 8,000 Liters

1 each

Sludge Process or Collection Tank

1 Cubic Meter

Sludge Stratification Tank

5000 Liters

Rinse tank

Rail tanker chiller

Chilled upto 2C

Battery

S.R.C valve & S.M.P valve

Butter
With the financial help from UNICEF, assistance from the
govt. of New Zealand under the Colombo plan, of Rs. 50
millions for factory to manufacture milk powder and butter
was planned. Dr.Rajendra Prasad, the president of India laid
the foundation on November 15, 1954. Shri Pandit
Jawaharlal Nehru, the prime minister of India declared it
open at Amul dairy on November 20, 1955.
Largest plant in Asia. ( atli-butli delicious amul)
They are paying Rs. 87/ton for AGMARK.
Today , market share 85% Amul , 5% britaniya & 10% others.
Here 100ton butter is prepared from 2lac lit. cream , everyday.

A
M
U
L

Process Flow diagram

Source: Internet

Ghee Section

Flow Diagram
PAST
WHITE BUTTER

CURDED MILK

CHURNING

WASHING

MELTING VAT

PRE-STARDIFICATION
Ghee Residue
HEATING

FILTERATION

CLARIFICATION

STORAGE TANK

PACKING

CREAM

BUTTER

Process for rework ghee


(A)

process for pouch


Separate the leakage pouch
Cut by clipper & take ghee in separate can.
filter ghee in can,
Transfer into melting vat
reprocess by heat
empty pouch wash two time by hot water & take it into scrap

(B)

process for tin


separate leakage tin & re-work tin
keep in tray for half an hour
cut tin & take ghee in separate tank
Transfer into melting vat & reprocess
empty tin wash two time by hot water & take it into scrap

Amul ghee is export in 14 countries


Self life
15 monthsAUSTRALIA, U.S.A., KR OMAN,
CP BAHRAIN, QUATAR, HONG KONG,
BRUNEI, CHINA, SINGAPORE, T. KUWAIT.
12 monthsABU DHABI, CP DUBAI, EGT
DHABI, CP DUBAI, EGT DUBAI, JAPAN

Laboratory
A. Amul-3 reception lab :
Following are the test of raw milk --1. Determination of titrable acidity in raw milk
2. Clot on boiling test
3. Alcohol Test
4. Methylene blue reduction test (MBR test)
5. Fat Test
6. Determination of phosphate activity

B. Central lab

1.
2.
3.

1.
2.
3.
4.

The dairy factory produces a variety of dairy products like


powder, butter, ghee etc. The various tests are carried out to
check its quality.
BUTTER
Following are the tests carried out to check the quality of
butter
Determination of moisture content in butter
Determination of salt content
Determination of SNF (curd) content in butter
GHEE
Following are the tests carried out to check the quality of the
ghee.
Organoleptic grading test
Moisture content
Free fatty acid Test
Iron test

Refrigeration
In refrigeration there are three diff. sections
1. -2 deg. C. system
Used for chilling the
water
2. 10 deg. C. system
Used for maintaining
the temperature
for ice silo.
3. 30 deg. C. system
Used for cold storage
and deep freezers
In amul lll 40% electricity consumed by refrigeration plant
Main parts of refrigeration sectios
1) Compressor
2) condenser
3) ammonia receiver
4) economizer

Boiler

In AMUL Plant, there are total four boilers and all are fire
tube type boiler.
The three boilers are having the capacity of 4 to 5 tonnes
steam production per hour and the fourth boiler having the
capacity of 10000 steam productions per hour.
The fuel gas that is used are off two types
1.Natural gas
2.Furnace oil.
The water used for boiler should fulfill the following
conditions
The pH is 8.5 to 9.5
Hardness is 10 to 40 ppm
Chloride content is 400 to 800 ppm.

Substation
Contract demand: 2800 KVA
Incoming Main power from two sub station :
1. Anand sub station
2. Mogar sub station
Main two part of dairy plant
1. Amul l & ll
2. Amul lll
For both plants separate sub station ,Anand & Mogar
electricty available for both dairy plants

Amul l & ll

Amul lll

Main 11 KV power supply comes in pole structure,

Metering point.

4 Nos.
High tension (HT) breaker
4 Nos.

11KV
2 Nos.
Transformer
2 Nos.
(1000 KVA)

440v
(1500 KVA)
Low tension LT breaker

Power control centre (PCC)


(MCCB OR Switch Fuse Unit (SFU))

Motor control centre (MCC)


(MCB, Relay, Contactor)

Motor (Machine)

ETP (Effluent Treatment Plant)


15 lac. Liters wastewater is treated per day.
Sr No.

Parameter

GPCB range

Amul maintained

1
2
3

PH
COD
BOD

6.5 to 8.5
100 mg/l
30 mg/l

7.5
80-90
20-24

4
5
6
7

S.S.
TDS
OIL
CL

100 mg/l
2100 mg/l
10 mg/l
650 mg/l

40-60
1100
3-6
140-165

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