1. PRODUCTION SECTION
MILK
Milk can be defined as clean, whole, fresh
lacteal secretion obtained by complete milking of one or more healthy animals,
excluding in at obtained within 15 days before and 5 days after calving or any
such period that may be necessary to render the milk partially colostrums free
and containing minimum prescribed percentage of milk and solid not fat (SNF).
|
CONTENTS
|
MILK (%)
|
COW MILK (%)
|
BUFFALO MILK (%)
|
|
WATER
|
86-85
|
86
|
82-83
|
|
FAT
|
3-5
|
4
|
6-8
|
|
PROTEINS
|
3
|
3.4-3.5
|
3-4
|
|
LACTOSE
|
4.5
|
4.9
|
4-5
|
|
MINERALS
|
0.7
|
0.7
|
0.7-0.8
|
|
SNF
|
-
|
9
|
9-10
|
PROCESSES INVOLVED IN MILK MANAGEMENT
1.
RAW MILK RECEPTION
DOCK (RMRD)
RMRD section is the part of the milk industry
where the raw milk is received from 325 societies & 3 chilling centers in
Kalanour, Batala, Tugal wala. Can of different societies are received at this
station. Cow milk cans are marked with yellow color and buffalo milk cans are
marked with red color. In RMRD section good quality of milk is received. In
RMRD section, milk is received in cans and vans are put on the conveyor belt.
Here each can is properly smelled and mixed with the plunger.
FLOW CHART FOR RMRD
 |
1. Flow chart Can Washer
•1.
•DARIN
•2.
•PRE-RINSE
•3.
•CAUSTIC RINSE
•4.
•
•DRAIN
•5.
•HOT WATER RINSE
•6.
•DRAIN
•7.
•STERILIZATION WITH STEAM
CAN WASHER
1.
MILK
PROCESSING
For
a good quality product proper processing is very important. Processing is done
in a sequence. The sequence operations in processing are as given below:
a. CHILLING
All incoming milk
is chilled first and then it is diverted to milk store tanks. Milk is chilled
below 4°C. The raw chilled milk is utilized for various products processing
operations. The chilled milk is stored in tanks called silo.
b. PASTEURIZING
Milk is pasteurized
to 80°C for 15 seconds & then immediately cooled below
4°C. The
pasteurizer has the following sections:
✓ Chilled water
Section.
✓
Regeneration 1 and 2.
✓ Hot air section
✓
Holding section.
The
pasteurizer is plate heat exchanger type consisting of many conducting plates
arranged parallel to form a network of many plates lying side by side.
Alternate plates are for carrying milk and hot water. The length & breadth
of plates flow rate are so adjusted to give proper contact time to milk for
proper pasteurization. The high temperatures short time (HIST) method is being
used here.
Pasteurization
& Standardization of Milk
Purpose: To pasteurize and standardize milk Scope:
Respective product section Responsibility:
Production
and Quality Assurance department
1. Ingredient:
1.1 Raw Milk-
Raw milk quality shall be checked for each silo / storage tank and certified by
QA before feeding to pasteurizer.
2. Equipments & Utilities Required
2.1 Storage Tank / Silo
2.2 Milk
pasteurizer
2.3 In-line
duplex filter
2.4 Cream separator
2.5 Cream Pasteurizer
2.6 Homogenizer
2.7 Pumps,
Valves & Pipe lines
2.8 C.I.P
system
2.9 Chilled
water (0 to 1°C)
22.10
Compressed Air (6 Kg / cm pressure)
22.11 Steam
(2.5 to 3 Kg / cm pressure)
2.12 Soft water (hardness < 10 ppm)
2.13
Electricity (Power Supply-3 phase 415 volt & single phase 230V)
3.
Procedure
3.1 For pasteurization milk should be heated at
76±2°C and cream should be heated at 88±2°C with holding time of minimum15
seconds.
3.2 Plant operators
will not change heating temperature without approval of production Manager /
Incharge.
3.3 Cream
separator and Homogenizer should be kept in line.
3.4 Before pasteurization, operation of flow
diversion valve should be checked.
3.5 Controls
and measuring instruments should be calibrated in fixed interval.
3.6 The
online recording of temperatures and forward flow should be monitored by the
Manager / Incharge production.
3.7 The
pasteurized milk should be stored in the cleaned milk storage tank / silo.
3.8 Pressure head of hot water, chilled water &
product should be maintained as per the design parameters of the pasteurizer.
3.9 Milk can
be standardized by using cream, skim milk, concentrate & reconstituted
milk.
3.10 C.I.P of pasteurizer should be done before and
after its use however the intermediate C.I.P should be done after 6-8 hours of
its continuous use. This time may vary depending upon the quality of incoming
milk.
3.11 Complete
pipe line, filters and storage tank / silo should be properly cleaned and
sanitized before the storage of pasteurized milk. Quality assurance staff will
certify its cleanliness before its use.
3.12 All the
CCP should be strictly maintained by production department and certified by the
quality assurance at the start of every shift.
3.13 MBRT and
Phosphatase test will be
conducted
at fixed interval.
3.14 Manual cleaning of
pasteurizer should be done after every six months however this time period may
decreased depending upon the quality of incoming milk and flow of milk.
3.15 Guidelines of GMP (as per IS 16021:2012) should
always be applied during Processing & Standardization.
4
Process Flow Chart
4
Process Flow Chart
Note:
Regeneration efficiency of pasteurizer should not be less than 90%.
C. CREAM SEPERATION
Milk after regeneration l-passes to cream separator. The cream from
cream separator goes to cream pasteurizer & from cream pasteurizer to cream
storage tank where as the skim milk
diverted to pasteurizers. Fat % in cream=35-40% Fat % in skim milk = 0.05-1%
Separator efficiency = 65-70%
d. CREAM PASTEURIZER
It is a plate exchange type of pasteurizer specially designed to
pasteurize cream at 90°C for 15 second. The pasteurized cream is then pumped in
the cream storage tanks, from here cream is sent to the butter section or it
could be sent to the balance tank when milk is standardized.
e. HOMOGENIZER
Homogenization is the process of making stable emulsion of milk serum by
mechanical treatment. It is referred to as the process of forcing the milk
through homogenizer with the object of subdividing the fat globules.
Homogenizer is a high pressured piston pump which is designed to subject the
liquid milk to a high pressure & and allow the product to pass through a
very special valve. This process breaks up the fat globules & increases the
ability of protein to hold water of hydration and also soften the curd. The
temperature of the homogenization is so chosen that is above the melting point
of fat (33°C) & lipase is deactivated (55°C). In routine practice the
temperature of homogenization chosen is 6570°C. Homogenization is carried out
in two stages. In the plant, milk is homogenized for preparation of VERKA
premium milk.
4.PRE-PACKING
SECTION
To protect contamination retard or prevent losses of the milk products have to be properly. In the plant liquid milk is filled in the pouches made of LDPE . it can be sealed at 150oc. The packaging is done by automatic fill & seal machine called pre-pack machine. Capacity of the machine is 3000 pouches per hour.
FILM SPECIFICATION
v
Package material – LDPE
v
Film width – 325mm
v
Film Thickness-55 microns
Procedure:
4.1 Processed standardized milk quality should be certified by QA to
meet the required specifications before packing.
4.2 Complete pipe line, balance tank and pouch filling machine should
be properly cleaned and sanitized before starting the milk filling and
completion of filling. Quality assurance staff will certify its cleanliness
before its use.
4.3 All the CCP should be strictly maintained by production department
and certified by the quality assurance at the start of every shift.
4.4 Operator will check all operational parameters and working of the
machine as per the checklist displayed and supervisor / in-charge will certify.
4.5 Weighing scale should be calibrated with the standard weights in
every shift by the operator and will be certified by the supervisor /
in-charge.
4.6 Pipe line and filling tubes
should be flushed with milk before starting the filling of milk in the pouches.
After segregating the first two pouches the third pouch of the machine should
be tested for its proper sealing. Also check the composition of milk filled in
the pouch. After confirming the composition of the milk packing should be
continued.
4.7 Before stacking the pouches
in the crates, supervisor / in-charge will ensure that crates are properly
cleaned (inside and outside).
4.8 Hygienic conditions of equipment and filling area should be
maintained.
4.9 During the packing, the
production staff will check the weight, length, coding and sealing of pouch
after every half an hour which will be counter checked and certified by the QA
after every an hour.
o4.10 The temperature of incoming milk for filling should not be more
than 3 C.
04.11 The packed milk should be transferred to cold-store and
dispatched at below 5 C.
4.12 Filled crates should be
stacked up to 10 crates in the cold store and temperature of the cold store
oshould be maintained at < 4 C. 4.13 Guidelines of GMP (as per IS
16021:2012) should always be applied during packing and dispatch.
5 Clearance
Procedure:
5.1 Milk quality (As per Specifications PS-QA-01 to PS-QA-07) shall be
checked and certified by QA before feeding to pouch packing machine.
5.2 Testing of packaging
material (Polyfilm and Crate) should be done by QA & Quality approval
should be done by the four member committee.
5.3 The final product to be
dispatched for market only after verifying its quality by QA Section.
6 Transportation
requirement:
Pasteurized packed milk shall be
transported in insulated / refrigerated vans depending upon the distance.
Before loading it should be assured by the marketing section that vehicle is
properly cleaned (inside and outside) and certified by the QA section.
2) PRODUCTS AND THEIR FORMATION
1. Whole Milk Powder (W.M.P.)/Skimmed Milk
Powder (S.M.P)
2. Raw Milk
i. Full Cream Milk(F.C.M.)
ii. Standard Milk (S.M.)
ili. Double Toned Milk (D.T.M.)
3.
Dahi (Curd)
4. Ghee
5. Panjeeri
6. Lassi
7. Kheer
8. Paneer (Cheese)
1.Whole
Milk Powder (W.M.P.) or Skimmed Milk Powder
(S.M.P) MANUFACTURING
Milk
powder is made in the powder plant, the plant consist of two parts.
EVAPORATOR
→ SPRAY DRYER UNIT
In the evaporator, the milk is concentrated at about 48% solid. The
evaporation from the milk takes under vacuum, which is maintained by the vacuum
steam. Steam is supplied as heating medium. The concentrated product at desired
concentration is continuously taken out from the evaporator. The concentrate is
then brought to spray drying chamber by spraying it to the spray nozzle with
the help of pressure pumps. The droplets of feed are atomized with the help of
high pressure nozzle & change to powder when they come in contact with the
hot air, which is supplied from the top the chamber. Fine powder is sucked
through the exhaust fan along with the exhaust
air & is then separated in the cyclone separator. Fine powder is received
at the bottom of the conical portion of the drying chamber. Powdered milk is
then collected and packed
FLOW
CHART OF MILK POWDER
1. Cyclone
For Calinderia
2. Cyclone
For Chamber
3. Suction
Pump
4. Atomizer
5.Recipeocating
feed pump
6. Bottom
valve of Drying Chamber
7.
Calinderia 1.
8.
Calinderia 2
9. Air
Control Valve
10. Packing
section
1. Ingredients
1.1
Pasteurized Skimmed milk for
skimmed milk powder
manufacturing with following specification:
a)
Fat (Max):0.10%
b)
SNF (MIN):8.0%
c)
MBRT (MIN): 6:00 Hrs
d)
Phosphatase test : Negative
e)
Alchol test (70%v/v):Negative
f)
Acidity:0.13=+\- 0.01% L.A
1.2Pasteurized
standard milk for milk powder with following specification:
a)
Fat : SNF_1:2.69
b)
MBRT(Min):6.00 hrs
c)
Phosphatase test : Negative
d)
Alchol test (70%v/v):Negative
e)
Acidity:0.13=+\- 0.01% L.A
2.Equipments
& Utilies Required
.Silo/storge tank
.Condensing & spray Drying Unit
.Powder sifter
.Powder Packing machine
.Hot air
.Steam
.Compressed air (6 kg/cm2)
.Chilled Water
.C.I.P system
.Electricity (415 v 3-phase & 230 v
single phase)
3. Packaging Requirme
1 Primary
Packing :Poly-liner, Poly-pack/ Laminate and Tins
2
Secondary Packing: CBX, Kraft paper bag
Procedure
·
Decomposition of pressurised skim milk
standard maths should be tested and certified by a to required specification
before condensing.
·
Control and measuring instruments should
be calibrated in fixed interval.
·
All the CCP should be maintained by
Production department and certified by quality assurance.
·
Weighing scale should be calibrated with
the standard wing in the every shift by the operator and will be carefully by
the supervisor shift incharge.
·
Hygenic condition of equipment and
feeling areas should be maintained.
·
Operator will check all operation
parameters and working of the machine as per the checklist display and
supervisors in shift incharge will carefully certified.
·
Complete pipeline storage tanks in low
balance and condensing June 2013 black and green unique should be properly
clean and sanitize before starting and after complete the operation Quality
Assurance staff will certified is cleanness before its use.
·
Pasteurized skim milk standardized milk
should be heated in high temperature at 90 plus minus 5 degree centigrade.
·
The outlet temperature of the product
after condensing should be a 47 + - 3 degree centigrade and banner reading
should be maintained at 22 + - 34 SMP and 15 + - 24 milk powder the concentrate
should be stored in the concentric tank/Vat.
·
The Concentrated Standardized/ skimmed
milk increase milk should be in 10 sec to the Optimizer spray nozzle through
feed pump.
·
The Drying of powder should be done by
adjusting the inlet and outlet for a temperature.
·
Powder Fins should be blown Back to
Drying chember through Virgo fluidized bed if agglomerates connected powder has
been prepared.
·
Cooling of powder should be done with
flat in coal air at the outlet of the Jaya skim milk powder should be back in
the KP bag with poly linear and milk powder should be packed in either paper
bag with pollen grains which should be stitched or intense with shoulder and
Nitrogen gas packing.
·
See IP of condensing unit should be done
after every 10 hour this time may vary depending upon the quality of the
incoming milk.
·
Dry cleaning of there should be done
after every 20 hour of continuous Run.
·
This sample should be tested
periodically to confirm the final composition by QA final products shall also
be tested by QA for its organoleptic test before dispatch.
·
Guideline of GMP (as per IS 16021: 2012)
should always be applied during manufacturing packing and dispatch.
Clearance procedure
1) Raw material the passphrase skim milk scanjet
Mila Ke Pite back poly poly linear and thin quality shall be checked by QA.
2) Final
product: define production be tested time to time to ascertain the specification
of the product.
3)
The final product should be this
page for market only after verifying its quality by QA sections.
Transportation
requirement
It should be transport by ambient
temperature.
Shelf
life:-minimum
12 month for SMP and milk powder in the form date of packing at ambient
temperature
2.
Raw Milk
Specifications
for Pasteurized Standardized Milk
Physical
Properties
|
Parameters
|
Standards
|
|
Colour
|
White
|
|
Flavour
and Taste
|
Clean
and Fresh
|
|
Dispatch
Temperature
|
<5°
C
|
Chemical
Specifications
|
Parameters
|
Standards
|
|
Fat
% (min)
|
4.5
|
|
SNF
% (min)
|
8.5
|
|
Acidity
% L.A. (max.)
|
0.135
|
|
MBRT
in hours (min.)
|
6.00
|
|
Phosphatase
Test
|
Negative
|
|
Protein%
|
3.00
|
|
Total
carbohydrates %
|
4.80
|
Microbiological
|
Parameters
|
Standards
|
|
TPC
(cfu / ml) (max)
|
30,000
|
|
Coliform
/ ml (max)
|
Nil
|
|
E.
coli / ml
|
Absent
|
|
Salmonella
/ 25 ml
|
Absent
|
|
Staph.
aureus / ml
|
Absent
|
|
Listeria monocytogenes / ml
|
Absent
|
.
Specifications for
Pasteurized Double Toned Milk
Physical
Properties
|
Parameters
|
Standards
|
|
Colour
|
White
|
|
Flavour and
Taste
|
Clean
and Fresh
|
|
Dispatch
Temperature
|
<5°
C
|
Chemical
Specifications
|
Parameters
|
Standards
|
|
Fat
% (min)
|
1.5
|
|
SNF
% (min)
|
9.0
|
|
Acidity
% L.A. (max.)
|
0.140
|
|
MBRT
in hours (min.)
|
6.00
|
|
Phosphatase
Test
|
Negative
|
|
Protein%
|
5.10
|
|
Total
carbohydrates %
|
3.15
|
Microbiological
|
Parameters
|
Standards
|
|
TPC
(cfu / ml) (max)
|
30,000
|
|
Coliform
/ ml (max)
|
Nil
|
|
E.
coli / ml
|
Absent
|
|
Salmonella
/ 25 ml
|
Absent
|
Specifications
for Pasteurized Cow Milk
Physical
Properties
|
Parameters
|
Standards
|
|
Colour
|
Yellow
|
|
Flavour and
Taste
|
Clean
and Fresh
|
|
Dispatch
Temperature
|
<5°
C
|
Chemical
Specifications
|
Parameters
|
Standards
|
|
Fat
% (min)
|
4.0
|
|
SNF
% (min)
|
8.5
|
|
Acidity
% L.A. (max.)
|
0.135
|
|
MBRT
in hours (min.)
|
6.00
|
|
Phosphatase
Test
|
Negative
|
|
Protein%
|
4.60
|
|
Total
carbohydrates %
|
3.10
|
Microbiological
|
Parameters
|
Standards
|
|
TPC
(cfu / ml) (max)
|
30,000
|
|
Coliform
/ ml (max)
|
Nil
|
|
E.
coli / ml
|
Absent
|
|
Salmonella
/ 25 ml
|
Absent
|
|
Staph.
aureus / ml
|
Absent
|
|
Listeria monocytogenes / ml
|
Absent
|
3. Dahi (Curd)
Preparation Of Culture For Dahi
Purpose: Procedure to prepare culture for Dahi / Lassi
Scope: Respective Product Section
Responsibility: QA
Section
Procedure to prepare Dahi / Lassi culture
with 200 U DVS culture (Varies from manufacturer to manufacturer):
For example
standard unit of DVS culture of 200 U for 2000 liters of milk; following
instructions should be followed:
1. One pouch
of DVS culture of 200U should be taken.
2. Distilled water should be sterilized in two
inoculation bottles of 2 liters capacity with 1 liter water in each bottle.
3. DVS culture pouch should be aseptically cut
and poured in one of the bottles having one liter distilled water at room
temperature.
4. It should
be mixed thoroughly for 5 minutes by shaking the inoculation bottle and volume
should be make up to 2 liter by adding 1 liter sterilized distilled water and
should be mixed properly.
5. This 2 liter culture should be divided in
to 1 liter + 1 liter in bottles.
6. Each 1 liter bottle is now ready for
inoculation in 1000 liter milk.
7. Such
prepared culture should be used immediately
Dahi Manufacturing
Purpose: To
manufacture and pack dahi as per the specifications.
Scope: Respective Product Section.
Responsibility:
Production and Quality Assurance Department.
1. Ingredients:
1.1
Pasteurized Homogenized Milk: The milk shall be standardized, pasteurized &
homogenized and shall meet the product specifications. 1.2 DVS Culture: As
recommended
2. Equipments & Utilities Required
2.1 Milk
storage tank
2.2
Homogenizer o
2.3 PHE with
10 minutes holding and milk outlet temperature 45-50 C
2.4 Double
Jacketed inoculation vat (capacity matching with packing machine so as to pack cultured
milk within 35 minutes after proper mixing)
2.5 Pouch, Cup & Bulk filling &
sealing machine o
2.6
Incubation Room to hold filled product at 42-44 C up to 4-4.5 hours.
2.7
Cold-store with blast room
2.8 Pumps, Valves & Pipe lines
2.9 Electricity (Power Supply 3-phase 415 V& Single phase 230V)
2.10 Voltage stabilizer
2.11 Soft water (hardness < 10 ppm)
22.12 Steam
(2 to 3 Kg / cm )
22.13
Compressed air (6 Kg / cm )
2.14 C.I.P
system
3.
Packaging Requirements:-
3.1 Primary packing:
Cups with aluminum foil as lid, Poly film & Bulk filling with aluminum foil
& plastic lid.
3.2
Secondary Packing: Corrugated Boxes with holes for all cup variants and Crates
for pouches.
4.
Procedure:
4.1 The
quality of the pasteurized standardized milk (As per PS-QA-08) shall be tested
by QA for its sensory, chemical and microbiological tests.
4.2 Complete
pipe line, balance tank, PHE, inoculation tank / vat and filling machine should
be properly cleaned and sanitized before and after completion of operations.
Quality assurance staff will certify its cleanliness before its use.
4.3 Operator will check all operational
parameters and working of the machine as per the checklist displayed and
supervisor / in-charge will certify.
4.4 All the CCP should be strictly maintained
by production department and certified by the quality assurance on daily basis.
4.5 Manual
cleaning of PHE should be done after every six months however this time period
may decreased depending upon the quality of incoming milk and flow of milk. 4.6
Controls and measuring instruments should be calibrated fortnightly.
4.7 The
online recording of temperatures and forward flow should be monitored by the
Manager / Incharge production.
4.8 Weighing scale should be calibrated with
the standard weights in every shift by the operator and will be certified by
the supervisor / in-charge.
4.9
Pasteurized standardized milk should be heated at 90 ºC for 10 minutes and the
temperature of milk coming out of the PHE should be at 45-50 ºC.
4.10 Temperature of milk should be 42-44 ˚C in
the inoculation vat at the time of inoculation of culture.
4.11
Addition of DVS culture (refer SOP for culture preparation) @ 100 units for
1000 liter milk (varies from manufacturer to manufacturer). The culture shall
be mixed properly for 10 minutes.
4.12 The
inoculation tank should be cleaned with hot water after every empty out and
proper C.I.P should be done after 8 hours along with pipes, PHE and packing
machine. 4.13 Cultured milk shall be filled in the clean cup / Pouch / Bulk
pack and should be sealed properly.
4.14
Hygienic conditions of equipment and filling area should be maintained.
4.15 The filled cups should be packed in
corrugated boxes and pouches should be stacked in clean perforated crates.
4.16 During
the packing, the production staff will check the weight, coding and sealing of
packs after every half an hour which will be counter checked and certified by
the QA after every an hour.
4.17 The packs should be transferred to
incubation room maintained at 42 to 44 ºC with proper circulation of hot air.
4.18 The acidity development should be checked
by QA section time to time at different points from each lot to ascertain that
the acidity reaches to 0.60 ± 0.02%.
4.19 The
product achieved required acidity should be transferred to blast cooling room
where temperature of dahi will come down at about 20ºC within 2 hours &
then it should be transferred 0 0to cold-store (< 4 C) to bring down the temperature
of product up to 4 C.
4.20 The
product should be dispatched at temperature less than 5 C with final acidity of
0.85 ± 0.05% L.A. The final product shall also be tested by QA for its body,
texture and organoleptic test before dispatch.
4.21 Guidelines of GMP (as per IS 16021:2012)
should always be applied during manufacturing, packing and dispatch.
5.
Clearance Procedure:
5.1 Milk Quality: The quality of standardized milk of
required specification (As per Specifications PSQA-08) shall be checked and
certified by QA section before inoculation of the culture.
5.2 During manufacturing: The filling of cup / pouch / bulk pack
should be completed within 45 minutes
after culturing. The control on acidity development in the filled packs
shall be monitored from the incubation room to ascertain development of
required acidity level (0.60% ± 0.02% L.A.).
5.3
Final product: The final product shall be tested for each lot to ascertain the product
parameters meeting the specifications of the product. The required acidity of
the final product should be 0.85 ± 0.05% of L.A.
5.4 The final product shall be released for
market only after verifying its quality by QA Section.
6. Shelf life: Shelf
life should be declared minimum 5 days from the date of packing when stored
ounder refrigeration below 5 C.
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