INDUSTRIAL TRAINING

AT

VERKA MOHALI DAIRY, MOHALI

REPORT ON

QUALITY CONTROL AND PRODUCTION MANAGEMENT

SUBMITTED BY:

SHWETA THAKUR

ROLL NO- H-2015-05-027

B.TECH. (Food Science and Technology)

Training period: 15.01.2019 to 14.05.2019

1
 DECLARATION

I hereby declare that the industrial training in Verka Mohali Dairy, Mohali is an
authentic record of my own work as requirements of 4 month training during the
period from 15.01.2019 to 14.05.2019 for the award of degree of Bachelor of
Technology. (Food Science and Technology), Chaudhary Sarwan Kumar Himachal
Pradesh Krishi Vishvavidyalaya , Palampur .

Place: Mohali SHWETA THAKUR

Date: 15.01.2019

2
 ACKNOWLEDGEMENT

The training opportunity I had with “Verka Mohali Dairy” was a great chance for learning and
professional development. Therefore, I consider myself as a very lucky individual as I was
provided with an opportunity to be a part of it. I am also grateful for having a chance to meet so
many wonderful people and professionals who led me through this training period. I perceive
this opportunity as a big milestone in my career development.

It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to

Mr.Udham Singh, G.M. (Verka Milk Plant MOHALI.), I am sincerely thankful to Mr. Sanjay
Chopra (Mgr. Prod.), Mr. Jitendra Singh (Mgr. Q.A.), Mr.Rajeev Kumar (Q.A), Mr.Sunil (Lab
Assistant), Mr.Amit (Doc Lab) for their guidance which were extremely valuable for my study
both theoretically and practically. I am also thankful to all the deputy managers for their valuable
guidance and support. I also thank all the operators and workers who really showed co-operation
and support.

Shweta Thakur

B.Tech. (Food Science and Technology)

3
 Index
DECLARATION 2

ACKNOWLEDGEMENT 3

INTRODUCTION TO ORGANIZATION 5-7

FLOWCHART OF MILK RECEPTION 8

SPECIFICATION TO GUIDE RMRD 9

TEST PERFORMED IN LAB ON RAW MILK RECEPTION 9

DIFFERENT SECTIONS IN VERKA 10

RAW MILK RECEPTION DOCK 10

GRADING OF RAW MILK 11

QUALITY ASSURANCE SECTION 11

FUNCTION OF DIFFERENT LABS 12

TEST PERFORMED IN LABS

 DOCK LAB TESTS 13-19

 BR TEST 20
 RM TEST 20-21
 QUALITY CONTROL LAB TESTS 21-25

MILK PROCESSING SECTION 26-28

EQUIPMENTS USED IN MILK PROCESSING 29

DAHI SECTION 30-31

KHEER SECTION 32-33

LASSI SECTION 34-36

PANEER SECTION 37-38

BUTTER SECTION 39

GHEE SECTION 39-42

CONCLUSION 42

4
 INTRODUCTION TO ORGANIZATION
The Punjab State Cooperative Milk Producers’ Federation Limited (MILKFED) came into life in the
year 1973 to improve dairy farming in the state of Punjab. The primary aim was to provide a
lucrative milk market to the state milk producers by value addition and marketing of produce.
Another of its objective was to provide technical inputs for the enhancement of milk production.

Though the federation was registered quite earlier, it came into its real form in the year 1983 when
the milk plants of the former Punjab Dairy Development Corporation Limited were granted to the
Cooperative Sector under Operation Flood. The move was carried out in the state to provide better
deal to the farmers and better products to the customers.

MILKFED is set-up as a three tier system with Federation as the apex body at the State Level, Milk
Unions at the District Level and Cooperative Societies at the village level. The organization has
continuously advanced towards its coveted objectives well defined in its by-laws.

Main Objectives of organization:

a. To ensure quality milk procurement at remunerative price coupled with improved animal
productivity for reducing cost of milk production for sustainable growth of the milk
producers.

b. To provide quality extension services at the door steps of milk producers.

c. To ensure Quality Assurance in procurement, processing & marketing and enhancing

efficiency in the entire value chain.

d. To ensure acquisition, development and retention of competent manpower.

e. To improve fiscal management by optimizing the returns on capital.

f. To ensure continual modernization in the entire value chain through effective leveraging
of technology.

g. To embrace innovation in the entire value chain for consumer delight.

h. To ensure continual expansion of distribution.

i. To enhance brand equity

5
THE ROPAR DISTRICT COOPERATIVE MILK PRODUCERS’ UNION
LTD.

VERKA MOHALI DAIRY,S.A.S. NAGAR,PUNJAB

Milk Union Mohali registered during 1978 and started functioning on Anand Pattern from
Sept.’1979. It purchases fresh Milk twice a day directly from Milk Producers by organising Milk
Producers’ Co-operative Societies (MPCS) at village level in entire Ropar & Mohali Distt. and
part of Fatehgarh Sahib and Patiala Districts. Presently, The Ropar District Cooperative Milk
Producer’s Union Limited, Verka Mohali Dairy is a front-line Milk Plant in Co-operative Sector
having installed handling capacity of 5,00,000 litres of Milk per day.

1210 functional milk producer co-operative societies formed at village level are supplying about
average of 3,62,000 litres of Milk per day. This milk procurement goes to about 5,20,000 litres in
a day during peak flush season. Fresh milk is procured directly from milk producers through
village level societies twice a day. The main function of this plant is to provide best quality of
Pasteurised Liquid Milk to the consumers in Chandigarh and its satellite cities.

Apart from Liquid Milk supply (Full Cream Milk, Std. Milk, Toned Milk, Double Toned Milk &
Skimmed Milk), this Plant also manufacture Ghee, Paneer, Curd, Plain Lassi, Kheer, Spiced
Lassi, Sweet Lassi, Raita. To safe guard the interest of esteemed consumers and our milk
producers, manufacturing of Verka sweets with pure Desi Ghee and Khoa in plant campus has
been launched. All the products are manufactured under the brand name of VERKA.

Being a viable unit with robust financial health, this plant pays dividend to all member societies
out of its earning every year.

6
 PRESENT STATUS OF PLANT

State Punjab

District Mohali

Address Verka Mohali Dairy, S.A.S. Nagar, Mohali

160055

Product Profile Standardised Milk, Full Cream Milk, Double Toned

Milk, Toned Milk, Skimmed Milk, Cow Milk, Ghee,
Paneer, Dahi, Lassi (Plain, Sweet and Spiced), Jeera
Raita, Kheer,
White Butter

Product Brand Name Verka

Marketed By The Ropar District Co-operative Milk Producers Union

Ltd., Verka Milk Plant, S.A.S Nagar (Mohali) – 160055
(PB).

Milk Handling Capacity 6 lakh litre/day

Number of societies under milk union 1210

Number of chilling centers 3 chilling centres

Milk routes 58

7
FLOW CHART OF MILK RECEPTION

Tanker

Weigh Bridge

Sampling

Sample approved Sample not approved

Unloading

Manual Automatic

Pumped to Deaeration Vessel

Storage Tank

Duplex Filters

Raw Milk Chiller (Milk Chilled to 3°C)

Pumped to RMST (Raw Milk Storage Tanks)

8
SPECIFICATION TO GUIDE THE RMRD

Alcohol test : Negative

Acidity : 0.11 to 0.14%

Adulteration : Negative

R.M. Value : 28-32

COB : Negative

Sodium content : less than 450 ppm

B.R. reading : 40-43

P.V. Value : 1-2

TESTS PERFORMED IN LABORATORY ON RAW MILK RECEPTION:

1) FAT test (By Gerber method)

2) SNF test (by lactometer)
SNF=CLR/4+0.22F+0.29
CLR= corrected lactometer reading at 27º C
F= fat of milk by Gerber method
3) Adulteration test (negative)
4) BR reading of milk (40-43 at 40ºC)
5) Sodium test of milk (upto 450 ppm)
6) RM value of milk (28-32)
7) Quantity: To be checked
8) Acidity
9) MBRT: for good quality raw milk is 2 hrs.

9
 DIFFERENT SECTIONS IN VERKA
 Quality control section

 Main lab

 Dock lab

 Bacteriological lab

 Milk processing section

 Processing

 Filling

 Curd section

 Kheer section

 Lassi section

 Paneer section

 Butter section

 Ghee section

Raw Milk Reception Dock

 Verka follows a strict system of quality assurance to maintain a high

quality of milk provided to the consumer.

 The milk is received from local societies at village level, where chilling
centres are installed.

 On the basis of some main tests the milk is graded into categories.

10
Grading of Raw Milk
 On the basis of physical condition and some test the milk is graded into four categories:

Types of Raw Milk Grades

Fresh raw Milk 1

Sour Raw Milk 2

Curd 3

Dirty Milk 4

QUALITY ASSURANCE SECTION

Quality Assurance

Dock Lab at ground floor Quality Lab

Chemical Microbiological AGMARK

11
 In the Plant there are three main labs:

• Dock Lab

• Quality Control (Q.C.) Lab

• Microbiological Lab

FUNCTIONS OF DIFFERENT LABS

DOCK LAB

1. Grading of incoming raw milk

2. Raw milk testing
3. Testing of outgoing pasteurized milk
4. Testing of processed milk stored in storage tank or silo
5. Cream testing
6. Buttermilk testing
7. Standardization of fluid milk
8. Checking of strength of detergent in crate washer

QUALITY CONTROL LAB

1. Sensory evaluation of milk and milk products

2. Checking the composition of milk products
3. Hardness of water
4. Checking the quality of reagents, packaging materials, glass wares for testing
5. Checking efficiency of waste water treatment
6. Controlling the cleaning of dairy equipments as well as sanitation of plant.

MICROBIOLOGICAL LAB

1. Checking the bacteriological quality of various types of milk & milk products.
2. Determine the types and number of microflora in air,water& various diryequipments pipelines.
3. Testing of keeping of milk & milk products.

12
AGMARK LAB

Checking quality of ghee so as to conform AGMARK Standards

TESTS PERFORMED IN LAB

Dock Lab

In Dock Lab raw milk, pasteurized milk, butter milk, Skim milk are checked w.r.t. the chemical
quality.

Various tests are performed over milk in this lab.

 Acidity Test
 MBRT Test
 Fat and SNF Test
 Adulteration Test

ACIDITY TEST

Bacteria that normally develop in raw milk produce more or less of lactic acid. In the acidity test the
acid is neutralised with Sodium hydroxide and the amount of alkaline is measured. From this, the
percentage of lactic acid can be calculated.

Procedure
• Take 10 ml of sample(can be milk, lassi, cream, dahi etc.) in 10 ml conical flask.

• Hold the flask against white surface.

• Add 4-5 drops of phenolphthalein to the sample and stir gently

• Titrate against N/10 NaOH solution

• Continue until the appearance of a light pink colouring which persists for 10-20 seconds
and down the volume of NaOH used.

So, %Acidity = volume of NaOH used (in ml)/10

13
Result :

Sample No. Acidity

1. 0.19

2. 0.15

3. 0.17

The milk with acidity 0.15 is the best milk.

MBRT TEST

It is indirect method of estimation of total bacterial content of milk. Instead of counting bacteria
directly, a correlation is made between the time required to reduce dye to colorless in milk.

Procedure
• To 10 ml of milk in a sterilized test tube add 10 ml of methylene blue dye. Plug with a

sterilized cork, invert the tube to mix the contents.

• Incubate at 37°C in a water bath.

• Note down the time in which the colour of dye gets disappear and that will give the MBRT time.

ESTIMATION OF FAT CONTENT

Fat can be determined using Gerber’s method or using a milkoscan

Gerber Method

Principle: When a definite quantity of sulphuric acid and amyl alcohol are added to a definite
volume of milk, the proteins will be dissolved and the fat will be set free which remains in liquid
state due to heat produced by the acid. The amyl alcohol used facilitates the separation of a clear fat
column. On centrifugation, fat being lighter will be separated on top of the solution.

Procedure for estimation of fat% of milk and lassi:

• Take about 10 ml of H2SO4(10% dilute for milk & 20% for lassi)in Butyrometer.

14
• Add slowly 10.75 ml sample (can be lassi or milk) in it.

• Add 1 ml isoamyl alcohol and adjust level with distilled water.

• Cap butyrometer with lock stopper.

• Centrifuge for about 5 minutes.

• Take reading of the % fat by reading the butyrometer.

ESTIMATION OF S.N.F. CONTENT BY LACTOMETER

Principle: The method is based on the Archimedes Principle, which states that when a solid is
immersed in a liquid it is subjected to upward thrust equal to the weight of liquid displaced by it and
acting vertically upwards. Lactometers are variable immersion type hydrometers and calibrated
beforehand with liquid of known specific gravity.

Procedure:
• Warm milk in lactometer jar at about 40˚C then cool at 15.5˚C.

• Immerse lactometer in jar and take C.L.R.

% SNF = CLR/4+0.2×fat+0.29

Fat% & S.N.F.% can also be estimated by using milkoscan before which the sample is heated to
a temperature of 40ºC

Observations:

Sample Fat C.L.R. SNF(%)

No.

1. 4.25 29.4 8.49

2. 3.5 26.4 7.59

3. 6.7 31 9.38

Sample 1 and 2 are of Packaged milk and Sample 3 is Raw milk

15
 DETECTION OF MAJOR ADULTERANTS IN MILK

• To overcome the increasing need of milk and milk products and to make maximum profit
there is increase in adulteration cases.
• In adulteration test we used raw milk in 2 test tubes for each test, one of them containing only
raw milk and the other one was added with the tested material.

TESTS FOR DETECTION OF ADULTERANTS

ALCOHOL TEST

The alcohol test is used for rapid assessment of stability of milk to processing.This test gives an
indication of the mineral balance of milk. The test aids in detecting abnormal milk such as colostrum,
milk from the animal in the late lactation, milk from animal suffering from mastitis and milk in
which mineral balance has been disturbed.

Procedure:

• Take 5.0 ml of milk in a test tube using graduated pipette.

• Add equal amount of 70% ethyl alcohol
• Close the mouth of the test tube with thumb and mix the contents well by inverting the test tube
several times.

Result :
Formation of any flakes on the wall of the test tube indicates positive test.

FORMALINE TEST
Procedure:

• Take 2.0 ml of milk in a test tube using graduated pipette.

• Add equal amount of 90% H2SO4 containing traces of Feric Chloride from the side of test tube
slowly.
Result:
 Voilet ring formed (+ve)
 Brown colour (-ve)

16
 DETECTION OF HYDROGEN PER OXIDE

Procedure:

 Take 10 ml of milk in a test tube using graduated pipette.

 Add 10 to 20 drops of vanadium pentoxide reagent
 Mix them properly
 Note the colour of sample

Result: Appearance of pink or red colour (+ve)

DETECTION OF HEAT STABILITY

Procedure:
 Take 10 ml of milk in a test tube using graduated pipette.
 Add 0.6 ml HCl (N/10)
 Mix well
 Boil for 5 minutes in boiling water

Result:
 Formation of clots (+ve)
 No formation of clots (-ve)

DETECTION OF DETERGENT
Procedure:
 Pipette 1ml milk in 15ml test tube.
 Add 1ml dye solution followed by addition of 2ml chloroform vortex for 15 sec and
centrifuge at 1100RPM for 3 minutes.
 Note the intensity of blue colour in lower and upper layer.

Result:
 More intense blue colour in lower layer (+ve)
 More intense blue colour in upper layer (-ve)

DETECTION OF MALTOSE

Procedure:
 Take 5ml milk and boil it.
 Add 0.5ml drops of 5% lactic acid.
 Cool and filter.
 Add 3 drops of 1% iodine solution in filterate.

17
Result:
 If colour changes to brown ( +ve)
 If colour remain golden yellow (-ve)

DETECTION OF NEUTRILIZER

In milk, sodium hydroxide, sodium carbonate and sodium bicarbonate are added by adulterators to
neutralize the developed acidity in milk.

Procedure:
 Take 2 ml Rosalic acid solution.
 Add 2 ml milk sample.
 If pink color appears, it indicates added neutralizer.

DETECTION OF SUGAR

Procedure:
 Take 2 ml of 0.5% Resorcinol solution.
 Add 2ml milk sample.
 Place it in boiling water bath for 5 min.

Result:
 Red colour (+ve)
 No change (-ve)

DETECTION OF GLUCOSE

Take strip for glucose detection and dip it in milk. If blue color persists, it indicates positive glucose.

DETECTION OF SALT
Procedure:
 Take 2ml of Silver Nitrate solution.
 Add few drops of potassium chromate and 2ml milk sample.
 Yellow color indicates positive salt test.

DETECTION OF UREA
Procedure:
 Take 2ml urea detecting agent (DMAB-Dimethyl Amino Benzaldehyde reagent) and add 2ml
milk.
 Deep yellow color indicates positive urea test.

18
 PHOSPHATASE TEST

Alkaline Phosphatase is an enzyme which is naturally present in milk, but is destroyed at a

temperature just near to the pasteurization temperature. Alkaline Phosphatase test is used to indicate
whether milk has been adequately pasteurized or whether it has been contaminated with raw milk
after pasteurization.

Principle: Based on the principle that the alkaline phosphatase enzyme in raw milk liberates phenol
from a disodium para-nitro phenyl phosphate and forms a yellow coloured complex at alkaline pH.
The intensity of yellow colour produced is proportional to the activity of the enzyme.

Procedure:
 Take 1 ml of milk sample.
 Put 5 ml of Phosphatase solution.
 Incubate it in water bath at temperature of about 37˚C.
 Check for colour change after 15 minutes.
 If colour changes then the milk is not pasteurized.

In the image Test tube on left side with pale yellow colour is showing pasteurised milk which is
having no alkaline phosphate activity and test tube on right side is showing colour change in case raw
milk having alkaline phosphate activity.

19
 ESTIMATION OF BR VALUE OF MILK SAMPLE

Vegetable oils, hydrogenated fats, animal body fats and their blends have been reported as
adulterants in milk and milk fat products. The elevation of butyro-refractometer (BR) reading of milk
fat by addition of different vegetable oils is used to detect adulteration of milk. . It should be between
40-43 for milk fat with no adulteration. The average BR reading of groundnut, cottonseed, corn,
sesame, sunflower, mustard, soya and castor oils are 59.81, 62.43, 64.50, 64.88, 65.25,65.64, 66.00
and 73.00, respectively.

Procedure:

 Take Al tubes and fill it with sample.

 Then keep these in centrifuge so that cream layer is formed on top.
 Then take the cream with the help of spatula and heat cream so as to make ghee.
 Then put drop of ghee in butyrometer.
 Note down the value of BR reading.

ESTIMATION OF SODIUM CONTENT OF MILK SAMPLE

Milk is being adulterated with sodium to increase S.N.F. So Sodium content is checked by ISE
sodium analyser. Sodium analyser is calibrated at 100 ppm & 1000 ppm of sodium. Sodium
content of milk should be between 350-450ppm.

Procedure for estimation of sodium content of milk:

Take 45 ml of milk and add 5 ml of ISA & then dip the probe of sodium analyzer in beaker. ON the
stirrer & wait till reading is stable , when ready is displayed . Note down the reading.

RM (REICHERT-MEISSAL) VALUE

It is the number of millilitres of 0.1 N sodium hydroxide or alkali solution required to neutralize the
steam volatile, water soluble fatty acids distilled from 5g fat under precise conditions specified in the
method.

This value is quite significant for milk fat, since it primarily measures the butyric acid and caproic
acid content in given fat. When compared to other fats this value for milk fat is high. So this helps in
identification of milk fat from other fats.

Value should be 28 to 32.

• Centrifuge the sample for 15 min.

• Separate the cream and heat it to make ghee.
• Take 5g of ghee in flask.
20
• Add 20 g glycerol, 2ml of 50% NaOH and 6 to 8 glass beads.
• Heat clarify the sample.
• Add 93 ml boiling distilled water followed by 50 ml 1 N H2SO4.
• Fix it with still head to distillation apparatus.
• Mildly heat the flask so as to form the golden ring on top.
• After that heat it properly so that distillation starts and 110 ml distillate is collected in round bottom
flask.
• Distillate is filtered and chilled.
• Titrate it against N/10 NaOH using phenolphthalein indicator.
• RM Value = (ml of NaOH used – 0.4) x 1.1

QUALITY CONTROL LAB

 In quality control lab sensory evaluation of milk and milk products is done, in which there is
testing of shelf life.

 A check is put over cleanliness of dairy equipments and overall sanitization of plant.

 The products produced in the plant are checked for their quality and shelf life before they are
sent to the market.

 Some of the main tests done in the labs are:

1. Hardness of water.
2. Curd acidity test.
3. Moisture test for paneer.
4. Fat test for paneer.
5. Total solid test for kheer.
6. Ghee test/ Free fat acidity.

21
 HARDNESS OF WATER

This test is performed to check the hardness of water i.e. whether the water used in various
production units is suitable to use or not.

Procedure:
 Take 100ml water sample in a flask.
 Add 1-2ml NH3 buffer.
 Add 2-3 drops of indicator (Phenolphthalein) to it.
 Titrate it against 0.02N EDTA solution.
 Blue colour marks the end.

Calculations
 Hardness =T.V. x 10
 When T.V. = 21.5 Hardness = 21.5 x 10 = 215 ppm

CURD ACIDITY TEST

Curd acidity test is a test to check the acidity in packed form of curd i.e. with increasing time the
acidity of curd increases and it becomes unfit to consume. So to check it the test is performed. Curd
Acidity test is same as in case of milk.

Procedure:
 Take 10 ml of curd sample in a china dish.
 Put about 5 -10 ml of water in the dish.
 Mix it properly.
 Add few drops of Phenolphthalein indicator in it.
 Titrate it with NaOH.
 Light Pink colour marks the end.

Observations:

Sample No. Acidity

1. 6.0
2. 7.3
3. 6.3

Result:
Sample no.2 is acidic in nature and sample no. 3 is with optimum acidity 6.

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 MOISTURE TEST FOR PANEER

This test is used to check the presence of moisture in paneer in packed form, as more moisture may
lead to microbial activity.

Procedure:
 Take an empty dish and take its weight as W1.
 Put about 3g of crushed paneer in it, weigh it and mark it as W2.
 Put the dish in oven for about 4 hrs.
 Measure the weight and mark it as W3.

Calculation:
 W2-W1=A
 W3-W2=B
 B/A x10= Moisture

Observations:

Sample W1 W2 W3 A B Moisture(%)
No.
1. 27.739 30.338 29.534 2.599 0.804 30.95

2. 33.966 38.864 36.189 4.898 2.676 54.61

3. 10.028 13.648 11.921 3.620 1.726 47.69

FAT TEST FOR PANEER

Fat test is carried out to determine the amount of fat in paneer.

Procedure:
 Take a butyrometer and tear it.
 Take paneer sample into butyrometer.
 Put 3g sample into butyrometer.
 Put 10 ml sulphuric acid and 1ml amyl alcohol and to maintain its level we have to add hot
water.
 Then centrifuge it for 5 mins for 12000pm.
 Note the fat reading.

Calculations:
Fat% =Fat x11.26/W

23
Observations:

Sample No. Weight of Fat Fat (%)

Sample(g)

1 1.6 3.9 27.45

2 1.5 4.3 32.27

3 1.6 3.5 26.27

TOTAL SOLID TEST FOR KHEER

This test is done to check the presence of total solids in kheer in packed form.

Procedure:
 Take an empty dish and take its weight as W1.
 Put about 3g of kheer in it, and mark it as W2.
 Put the dish in oven (30○C) for about 4 hrs.
 Measure the weight and mark it as W3.

Calculations
 W2-W1=A
 W3-W1=B
 %T.S.=B/A x100

Observations:

Sample W1 W2 W3 A B T.S.
No.

1. 26.8056 31.0029 27.9556 4.1973 1.1500 27.4

2. 23.2825 27.8048 24.5351 4.5223 1.2526 27.7

3. 12.7029 16.7761 13.8230 4.0732 1.1201 27.5

24
 GHEE TEST/ FREE FAT ACIDITY

This is the test to check the quality of ghee/fat in terms of acidity.

Procedure:
 Take the sample butter to be tested.
 Heat the sample until it gives brown golden shades.
 Prepare a solution by adding 50 ml ethanol and 2-3 drops of phenolphthalein.
 Now neutralize it with N/9 NaOH.
 Take about 10g of ghee.
 Mix the solution prepared in 10g of ghee.
 Heat to boil.
 Then add NaOH to that for titration.

Observations:

Sample No. Acidity(%)

1 0.27

2 0.44

3 0.30

Result:
The normal value of acidity is 0.3 %, which indicates the good quality of ghee, whereas the increased
acidity means the rancid ghee.

25
 MILK PROCESSING SECTION
PASTEURISED MILK

Verka Milk is pouch packed and available in many variants for the convenience of its consumers
thus providing them fresh and healthy milk every day. It is pasteurized in state-of-the-art
processing plants and meets the PFA standards. Pouch Milk is available in an array of variants;
Full Cream, Standard Milk, Toned, Double Toned, Skimmed, Cow Milk.

26
FLOW CHART OF MANUFACTURING OF PASTEURIZED &STANDARDIZED
MILK

27
Composition of Various Variants Of Pasteurized And Standardized Milk
Manufactured By Verka:

Nutritional Standardized Full Toned Double Skimmed Cow

Information Milk Cream Milk Toned Milk Milk
per 100 ml Milk Milk

Energy value 72.0 87.0 58.0 46.0 36.0 67.0

(kcal)

Total Fat (g) 4.5 6.0 3.0 1.5 0.5 4.0

Saturated fat 2.9 3.8 1.9 0.96 0.32 2.5

(g)

Trans fat (g) 0.0 0.0 0.0 0.0 0.0 0.0

Cholesterol 10.8 14.4 7.2 3.6 1.2 9.6

(mg)

Total 4.8 5.1 4.8 5.1 5.0 4.6

Carbohydrates
(g)

Proteins (g) 3.0 3.15 3.0 3.15 3.0 3.1

Minerals (g) 0.7 0.75 0.7 0.75 0.7 0.8

Added - - 77 77 - -
Vitamin A
(IU)

Added - - 55 55 - -
Vitamin D
(IU)

SHELF LIFE OF PASTEURISED MILK: 2 days from the date of manufacturing when
stored refrigerated below 5ºC

28
 EQUIPMENTS USED IN MILK PROCESSING

PASTEURIZER

It is device used to pasteurize the milk i.e. heating at 63○C for 30 min or 70○C for 15 sec in approved
and properly operated equipment. At one end of the device the temperature is 75-80○C and at the
other end it is 4-5○C, i.e. instant cooling of milk is done after exposure to high temperature which
kills almost all germs in milk.

HOMOGENIZER

Homogenization is a process where in fat globules are broken down to 2 microns or less under high
pressure.
 It consist of high- pressure piston pump that forces the milk and thereby subdivided into
smaller particles of more uniform size.

CREAM SEPERATOR

It is a device which separates cream from the milk by means of a set of plates which rotate around a
central axis using centrifugal force.
 There are 135 plates in each cream separator.
 Cream and skim milk are obtained.
 After extraction cream is chilled to 4-6○C through plate chiller.

STORAGE TANK

To store the milk in different states like raw, chilled, pasteurized and standardized.
They have capacity of 10000-20000 liters.

MILK PACKAGING

 10 machines of packing are used each of which has two packing sections.
 Each machine has capacity to pack 1000 liters of milk per hour i.e. 2000 pouches of 500ml
per hour.

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DAHI SECTION
Verka Dahi is made from pasteurized milk and packed in advance Dahi packing facilities. Made from
pasteurized toned milk with 10.5% SNF, Verka Dahi meets the requisite FSSAI standards. It is ideal
for daily consumption as it provides calcium for strong bones and teeth. It provides protein for active
life and growth and helps in improving digestion.

INGREDIENTS

1. Milk: Fat 3% min; SNF 10.5% min

2. Culture : Freeze dried cultures

Companies providing cultures are CSL (Italy), CHR Hansen (Denmark), and Danisco (France)

COMPOSITION OF DAHI

Nutritional Information Per 100 ml*

Energy Value (kcal) 67

Total Fat (g) 3.0

Saturated fat (g) 1.9

Trans Fat (g) 0.0

Cholesterol (mg) 7.2

Total carbohydrate (g) 5.9

Added Sugar(g) 0.0

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Protein (g) 3.7

Minerals (g) 0.9

Calcium(mg) 150

SHELF LIFE 7 days from the date of manufacturing when stored refrigerated below 5ºC

FLOW DIAGRAM OF DAHI

Raw Chilled Milk

Pasteurization and Standardization of milk (Fat-3% min and SNF-10.5% min)

Storage in PMST storage (Min. 8 to Max. 24hrs at below 5°C)

Heating to 90 +/-2°C for 5 mins with outlet temperature of milk at 43 +/-1°C with homogenization at
2000/500psi

Inoculation vat @ 200 units/ 2000lts of milk and mixing for minimum 20 mins before filling starts

Filling in Polystyrene cups / Pouches / Matka

Incubate in incubation room at 42 to 44°C till % L.A. reaches 0.65-0.75%

Cold storage through Blast cold room till product reaches 5°C

Dispatch in insulated vehicle

31
KHEER SECTION
Kheer is also known as Basundi, is an Indian Dessert prepared by the partial dehydration of whole
milk in a karahi over fire together with sugar and usually rice or occasionally semolina. It is very
popular in Punjab and whole northern region.

Verka Kheer is a perfect combination of taste and health. Made with finest ingredients, Verka kheer
is immensely liked and is gaining new heights of popularity. It provides calcium for strong bones &
teeth and provides protein for active life and growth. Available in affordable and convenient cups, it
is a perfect on the go dessert.

INGREDIENTS

1. Pasteurized Standardized Milk which shall meet following specifications:

a) Fat 3.0% +/- 0.05%
b) SNF 10.0% +/- 0.05%
c) MBRT: min. 6.00 hrs
d) Phosphatase test: Negative
e) Acidity% (L.A.) max. 0.145
2. Rice – Basmati half piece of reputed brand (6 months to 12 months). It should be free
from extraneous matter.
3. Sugar – as per IS 1151:2003
4. Green cardamom – as per IS 1877:1985
5. Sodium Benzoate – (IP grade/ IS 4447:1994)

SHELF LIFE Shelf Life of Kheer is 10 days when stored refrigerated below 5ºC.

FLOW DIAGRAM OF KHEER MANUFACTURE

Pasteurized Standardized Milk (Fat 3.0% +/-0.05%; SNF 10.0% +/-0.05%)

Heating with vigorous boiling and continuous stirring (for 1 hour)

Separate15 to 20 kg milk and add 100g Cardamom powder, 12.8 kg sugar and 15 g Sodium Benzoate

To rest of milk heat for 5 to 10 min., and add 7.2 g rice (properly washed)

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Boil with continuous stirring till it attains desired concentration (80% of total intake material)

to this after 1 hour add previously separated and prepared 15 to 20 kg milk after filtering

Gentle boiling with continuous stirring for about 15 min.

Transfer to double jacketed hopper to cool to 50 to 55°C

Kheer filling and sealing machine

Storage below 5°C in cold store

Packing in corrugated boxes and dispatch

33
LASSI SECTION

Lassi is a cool refreshing milk based drink. Its a 'perfect thirst cruncher and best alternative for
aerated drinks. In addition, Lassi contains Probiotic bacteria that helps boost digestion.

PLAIN LASSI:

Verka Plain Lassi is a refreshing drink that can be savoured anytime. Made from Fresh Verka Milk,
Plain Lassi also makes for a great accompaniment to your food.

SPICED LASSI:

Verka Spiced Lassi contains jeera, chilli & ginger which makes for a great drink that is both tasty and
energizing. The lassi that best suits the palate of North Indians is a loved drink during summers.

SWEET LASSI:

Verka Sweet Lassi is renowned for its taste and is a best substitute for cold drinks during summers.
The lassi is processed using fresh curd and makes for the best of refreshments.

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Ingredients Required:

• Dahi made from Standardised milk

• DVS Culture
• Pasteurised Soft water
• Sugar
• Spiced powder
• Edible common salt

Specifications of milk for Lassi:

Parameters Standards

Fat% Plain Low Fat/Spiced/Sweet

Lassi

2.1±0.05 1.1±0.05

S.N.F.% 8.50±0.05 7.80±0.05

Acidity % (as L.A.) 0.13

MBRT in hours (min.) 6.00

Phosphatase test Negative

Shelf life of Lassi: 6 days from date of manufacturing when stored refrigerated below 5ºC

FLOW DIAGRAM OF LASSI MANUFACTURING

Standardized pasteurized milk (Fat /SNF Min. 4.5/8.5%) for curd from PMST

Heating of milk by PHE 90±2ºCfor 5 min with outlet temperature of milk at 44ºC with
homogenization at 2000 & 500 psi

Inoculation of culture at 42-44ºC & setting the curd LA acidity 0.80-0.90%

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Adding pasteurized water (equal to amount of water) & agitation with circulation of chilled water in
jacket to arrest acidity development

Addition of remaining pasteurized chilled water

Storage Tanks for packing in pouches

Packing in FFS machines

Cold storage at max. 5ºC

Dispatch in insulated van

36
PANEER SECTION

Chhana or paneer means the product obtained from the cow or buffalo milk or a combination
thereof by precipitation with sour milk, lactic acid or citric acid. It shall not contain more than
70.0 per cent moisture and the milk fat content shall not be less than 50.0 per cent of the dry
matter. Milk solids may also be used in preparation of this product. Traditionally Paneer is a
variety of pressed channa, used for preparing cooked vegetable dishes.

Ingredients specifications:

• Pasteurised Standardised milk

a. Fat 5.00±0.05% and S.N.F. 8.60±0.05%
b. MBRT min. 6.00 hours
c. Phosphatase test: Negative
d. Acidity (L.A.) 0.13 ± 0.01%
• Citric Acid as per IS 13186:1991

COMPOSITION OF PANEER OF VERKA

Fat 22.5 %

Protein 18.5%

Carbohydrates 3.0%

Minerals 0.9%

Energy value 289al

Shelf life of paneer: 6 days from the date of manufacturing when stored refrigerated below 5º

37
 FLOW DIAGRAM OF PANEER MANUFACTURING

Standardized milk for paneer fat-5% (Min.), SNF-8.6%(Min.)

Heating by PHE 90 ±2ºCwith outlet temperature of 76±2ºC

Filtration and transfer of milk to straining vat

Addition of Citric acid @0.16% in water/whey at 74+/-2

Straining of coagulum and draining of whey

Hooping in Muslin cloth -lined hoops

Pressing for 5-6 mins at 3-4 kg/sq. cm under pneumatic pressure

Cutting into blocks

Dipped in pasteurized & chlorinated chilled water (At <10ºC for min. 60-90 minutes)

Cut into pieces & weighing (200gm manually)

Packing of 200g paneer packets through multivac machine

Cold storage at max. 5ºC

Dispatch in insulated van for local sale or Refrigerated van for distant place sale

38
BUTTER SECTION

• Receiving of Raw Milk

• Pre heating and Filtration
• Centrifugal Separation
• Cooling of Cream
• Ageing of Cream
• Cream Feeding into Churn.
• Churning of Cream into Butter
• Removal of Butter Milk

GHEE SECTION

Ghee means the pure clarified fat derived solely from milk or curd or from desi (cooking) butter or
from cream to which no coloring matter or preservative has been added.
The standards of quality of ghee produced in Punjab as per FSSAI:
1. ButyroRefractometer reading at 40°C : 40.0 to 43.0
2. Minimum Reichert Value: 28
3. FFA as % oleic acid (max.): 3%
4. Moisture (max.): 0.5%

Produced in utmost hygienic conditions, Verka ghee is a rich source of vitamins and antioxidants that
stimulate bone metabolism and body growth. The ghee is made from fresh cream and has a natural
flavor and mouthwatering aroma.

SPECIFICATIONS FOR GHEE

Physical properties

Parameters Standards

Color Yellowish white

Body and texture Uniformly granular without any greasiness

Flavor and taste Clean, fresh and pleasant

Residue Nil

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Chemical Specifications

Parameters Standards

Moisture% (max.) 0.30

FFA% (max.) as oleic acid 3.00

B.R. reading (at 40°C) 40 – 43

R.M. Value (min.) 28.0

Polenske Value 1.0 – 2.0

Baudouin test Negative

Total Fat (min)% 99.70

FLOW DIAGRAM FOR GHEE PROCESSING

Melted butter (Kettle 1 and 2)

Settle it for half an hour

Fat on upper layer and buttermilk settles down

Cooking of fat at 108°C

Stand it for half an hour

Pump to Pre-Stratification tank

Keep it there for half an hour

40
 Pass through clarifier

Keep it in ghee storage tank

Filling and Packing next day

Storage of ghee in granulation room at 20-21°C

Storage and Dispatch

PRODUCT VARIANTS

1. Cekatainer (900 g)- 1litres

2. Tin (1 litre) = 900 g ghee at 45°C (Weight of container is 98 g)
3. Tin 15 kg = 16.65 litre at 45°C

NUTRITIONAL INFORMATION OF GHEE

Nutritional Information Per 100 g*

Energy Value (kcal) 897

Total Fat (g) 99.7

Saturated fat (g) 64.0

Trans Fat (g) 0.0

Cholesterol (mg) 240.0

Total carbohydrate (g) 0.0

Added Sugar(g) 0.0

Protein (g) 0.0

41
Minerals (g) 0.0

Vitamin A (mcg) 450

SHELF LIFE 12 months of tin packing and 9 months of cekatainers/monocartons/pouches when

stored in cool and dry place.

CONCLUSION
Based on the observation during my training at VERKA MILK PLANT, Mohali, it can be concluded
that the fluid milk products manufactured here are of high quality and are highly acceptable to the
consumer. The management is dedicated to manage the affairs correctly and accurately. There is
proper coordination among the workers and management, which helps the plant to run smoothly. The
behaviour of all workers and technical staff and official staff is appreciable.

In ecent times plant has increased its earning and improved its position by creating innovative
approaches. Milk reception is computerized to eliminated weight variation and % of fat and SNF
variation so that producer can get correct amount of payment. Milko-scan is provided by plant to its
BMC’s and chilling centres for accurate fat and SNF measurements. However there is scope for
further improvement.

 Marketing wing should be made strong enough to cater more areas under its marketing area
within the country and abroad.

 Maintenance schedule of milk plant machinery should be followed strictly to avoid any
production losses.

 Unnecessary expenditure on costly equipment should be avoided.

 R&D wing may also contribute in bringing the union in more profit by introducing some new
products, which have reasonable profit margins.

Lastly, from the present status of this plant, it can be said that with positive and creative thinking of
management and a strong will power of each staff of the plant, can easily raise the Mohali milk union
to the legendary one in the world of dairying.

As a trainee, it should be confessed that it is appropriate place conducting complete, practical based
training.

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