CHAPTER I

INTRODUCTION

1.1 INDUSTRY PROFILE

Indian Dairy has been involved in the dairy business since many years. We take pride in
introducing as one of Indias leading manufactures, exporters and suppliers of dairy product, we
at Indian dairy have shown an new way of living- a healthy way of living. We have wide range
of product catering to people of all age. We are continuously striving for synergy between
technology, system and human resource to provide product and service that meet the quality,
performance and pride aspiration of customers. Indian Dairy one of the leading manufacturer &
exporter of Skimmed Milk Powder, Desi Ghee, Condensed Milk , Casein, Full cream milk
powder, Dairy whitener, Palm kernel oil, White butter, Lactose, Glucose, Dematerialized whey
powder and all kind of dairy products, has emerged as the indubitable winner of dairy industry.

Dairy industry is the most ancient of India in which dates back to the mythological era of
Lord Krishna and King Virata. Undoubtedly, it can be said that there exist no other substances
that can substitute milk so far, as the whole some nutritious food is concerned. It had its
profound influence over the economy of rural population both in the past and in the present times
too.

As stated, even in the present day trend in the economy, proves the importance of the
Dairy Industry as a powerful tool of social and economic changes. As defined in the democracy,
welfare of the people means welfare of the government. In the process of evaluation under the
condition of democracy slowly the co-operative movement took the shapes and leaps in the
Dairy Development in the country. Co-operative movement has its initial rules in the field of
dairying in Anand, Gujarat State moved potentially to the other regions for the people.

Milk is the only natural product, which is a complete source of food; its nutritional
potential is unsurpassed by any other food used by man. The proteins in milk are ideal in quality
and balance top satisfy human amino acid requirements. The contents of mineral and vitamin c

1
is unique, not only in proportion but also in quality with the exception of vitamin c and iron,
milk provides all the nutrients essential for mans growth and development.

Milk is not only a complete food, but also quality of its nutrients both enhances and
extends many nutrients present in proper quality for example the amino-acid pattern and content
of milk proteins are such at they can supplement and good for the deficiency of most Cereal
proteins. The supplementing cereals with milk, improve the quality and quantity of the protein
supply.

According to Prof.N.J.Rope man of Haivard medical school. Milk is the only single
article of food that fairly represents the complete diet. It has no equal. Foe promotion of
nutritional development. Milk is also a cheap source of animal protein. It is on this account milk
become an essential integral part of Indian food to both vegetarians and as well as to non-
vegetarians either directly as milk or indirectly through its various products.

Thus in effect one should remember that it is the protein and other Casenual
micronutrients such as vitamins and minerals, which are the ingredients of the Chiefly Solids-
Non-Fat (SNF) part of the milk that is important in milk rather than fat to weigh the nutritional
value of milk.

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MILK CONSTITUENTS:

Milk constituents are mainly divided into three groups namely a) Water b) Fat
c)Solid-Not-Fat(SNF). The Constituents Other than water are called Total Solids (T.S). Total
Solids minus the butterfat are termed Solid-Not-Fat. All the constituents except the fat are known
as milk serum.

BUTTERFAT:

The Fat-exist in milk as an emulsion. Butter fat globules are in the form of small
spherical myriads of 0.1 to 20 microns. The size and arrangement of the globules affect the
creaming ability of milk, the viscosity of cream, and the whipping ability of cream and the
churning of cream to butter .

Butterfat is very rich source of energy and also a good source of vitamins A and D. Butterfat is
one of the principle constituents of almost all dairy products.

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PROTEINS:

The three principle classes of proteins in milk are casein, lactalbumin and lacto Globulin.
The casein accounts for 80% of the total protein content, that lactalbumin and lacto globulin
about 20%.

CASEIN:

Casein is a protein, which is found in no other product than It exists in milk with calcium
casein ate. The is present in milk in a v colloidal dispersion. Because, Casein a Protein, it
supplies the body the muscle g material, casein when converted into sodium, casein are, is used
Lrce of protein in many of the milk product.

LACTOSE:

Lactose a carbohydrate found only in milk is synthesized in mammary glands. Lactose

serves the body as a source of energy, but it is not a rich as a butterfat in this respect. lactose is
easily changed by bacterial action to lactic acid, a change that causes taste sour.

MINERAL CONSTITUENTS:

The mineral constituents are salts score to 0.8% of the total weight of the milk. The
potassium and chlorides of milk are in solution, where as the calcium. Phosphorus and Chlorides

4
Milk minerals are very essential as foods are the young, as they help to build up bones and
promote development of it is an important essential for children.

INDIAS CURRENT STANDARDS:

The following are the standards for cities or towns with population greater than 1lakh people:

Every person with more than five cattle kept for the purpose of profit must be registered
with the veterinary department of the state government of a local authority specified by
the state government.
Every registration application must supply full information about the number and types of
animals to be kept, the size of the area in which they will be kept, flooring and
ventilation, food and water supply, disinfection, drainage, waste disposal and other
relevant details.
If the registering authority is satisfied about the welfare of the animals, the registration
certificate is valid for three years, after which an application for renewal must be made.
Every registration certificate is valid for three years, after which an application for
renewal must be made.
If the premises are not properly maintained, the registration can be cancelled. Wherever
milch cattle are kept, the owner must display a copy (in the local language) of Section 12
of the Prevention of Cruelty to Animal Act, which prohibits the use of phooka and doom
dev.
Every registered premise may at any time be inspected by an authority veterinarian or
public health officer of the local or state government.

DAIRY INDUSTRY IN INDIA:

More than 2500 million people economically active in agriculture in the world. Probably
75% of them are wholly or partly dependent on livestock farming. India which has 66% of
economically active population engaged in agriculture. It derives 31% of GDP from agriculture.
The share of livestock is estimated at 21% of total agriculture sector.

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HISTORY OF INDIAN MILK INDUSTRY:

Organized milk handling was made in Indian with the established of military dairy farms,
with his

Handling of milk in co-operative milk unions established all over the country on a small
scale in the early stages.
Long distance refrigerated rail transport of milk from Anand to Mumbai since 1945.
Pasteurization and bottling of milk on a large scale for organized distribution was started
at Aarey in 1950, in Calcutta (Haringhota) 1959, in Delhi 1959, in Madras 1963, etc
Establishment of milk plants under the 5 year plan for dairy development all over India.
Their main aim was to produce more, better and cheaper milk.

ABOUT INDIAN DAIRY SECTOR:

Dairy development in India has acknowledged the world over as one of modern Indias
most successful development program. India is the second largest milk producing country with
anticipated production of about 78 million tons during 1999-2000.The milk surplus states are
Uttar Pradesh, Punjab, Haryana, Rajasthan, Gujarat, Andhra Pradesh, Karnataka and Tamil
Nadu.

NATIONAL DAIRY DEVELOPMENT BOARD

The National Dairy Development Board (NDDB) was created in 1965 for fulfilling the
desire of the people. Lal Bhadur Shastry the Prime Minister of India who extends the success of
the kaira co-operative milk producers union (AMUL) to the other parts on India.

NDDB has now integrated 96,000 Dairy co-operatives which are known the Anand
pattern, linking the village society to the state federation in a three-tier structure. NDDB
launched its perspective plan in 2010 with the following thrust areas:

Quality Assurance
Productively Enhancement
Institution Building
National Information

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DAIRY INDUSTRY IN INDIA:

Dairy development in India has been acknowledged the world over as one of the
most successful development program. India is the second largest milk producing country with
anticipated production about 78 million tons during 1999-2000.

The milk surplus states in India are Uttar Pradesh, Punjab, Haryana, Rajasthan, Gujarat,
Maharastra, Andhra Pradesh, Karnataka and Tamilnadu. The manufacturing of milk product is
concentrated in these milk surplus states.

Dairy sector has assumed a great significance by generating income not only to the rural but
also to the urban and semi-urban population in the state especially to the women sector folk by
providing self employment opportunity. Milk and milk products provides essential nutrition to
all walks of life. It provides the main source of income next to agriculture. In a tropical industry
like India .agriculture may fail sometimes, due to monsoon failure but dairying never fail and
gives then regular, steady income.

The state diary development department was establishment in 1958.The administrative and
stator controls over the entire milk cooperative in the state were transferred to the dairy
development was made at the functional registrar under the Tamilnadu cooperative societies act.

With the advent of Anand pattern in Tamilnadu, Tamilnadu cooperative milk producers
federation limited was registered on 1st February 1981.The commercial activities of the
department such as procurement, processing, packing and the sale of milk to the corporation
limited were transferred to the newly registered Tamilnadu cooperative milk producers
federation limited.

In the wake of the liberalization policy, private diaries have entered in the field of dairying.
As per the direction of Honorable Chief Minister of Tamilnadu high priority has been given for
improving the performance of cooperatives. Milk producers cooperatives societies, union and
federation in the state of Tamilnadu have made significant achievement.

The dairy sector in the India has shown remarkable development in the past decade and
India has now become one of the largest producers of milk and value-added milk products in the

7
world. The dairy sector has developed through co-operatives in many parts of the State. During
1997-98, the State had 60 milk processing plants with an aggregate processing capacity of 5.8
million litres per day. In addition to these processing plants, 123 Government and 33 co-
operatives milk chilling centers operate in the State. With the increase in milk production
maharashtra now regularly exports milk to neighboring states. It has also initiated a free school
feeding scheme benefiting more than three million school children over 19,000 schools all over
the State.

Two fold objectives of the diary development department are:

Assure a remunerative price of the milk produced by the milk producers societies through
a stable ,steady and well market support.
Distribution of quality milk and milk products at reasonable price to the consumers.

Functions of the diary development department:

The main function of the diary development department are organization of societies,
registration of societies, supervision and control of primary milk cooperative, District
cooperative milk producers union and Tamilnadu cooperative milk producers federation.

The diary development exercise statutory functions like inquiry, inspection, surcharge and
super session, appointment of special officers, liquidation and winding up of dormant societies
etc...The commissioner for milk production and diary development, Deputy Milk commissioner
and circle deputy registrars are vested with quasi- judicial power in respect of settlement of
dispute, appeal, revision and review under various provisions of Tamilnadu co-operative
societies act 1983 and rules made there.

STRUCTURE OF THE INDUSTRY

Most of the countries produce their own milk products, the structure of the dairy
industry varies in different parts of the world. In major milk-producing countries most milk is
distributed through wholesale markets. In Ireland and Australia, for example, farmers' co-
operatives own many of the large-scale processors, while in the United States many farmers and
processors do business through individual contracts. The United States, the country's 196
farmers' cooperatives sold 86% of milk in the U.S. in 2002.

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 This was down from 2,300 cooperatives in the year 1940s. In developing countries, the
past practice of farmers marketing milk in their own neighborhoods is changing rapidly. Notable
developments include considerable foreign investment in the dairy industry and a growing role
for dairy cooperatives. Output of milk is growing rapidly in such countries and presents a major
source of income growth for many farmers.

As in many other branches of the food industry, dairy processing in the major dairy
producing countries has become increasingly concentrated, with fewer but larger and more
efficient plants operated by fewer workers. This is notably the case in the United States, Europe,
Australia and New Zealand. In 2009, charges of antitrust violations have been made against
major dairy industry players in the United States.

Government intervention in milk markets was common in the 20th century. A limited
anti-trust exemption was created for U.S. dairy cooperatives by the Capper Volstead Act of
1922. In the 1930s, some U.S. states adopted price controls, and Federal Milk Marketing.

Plants producing liquid milk and products with short shelf life, such as yogurts, creams
and soft cheeses, tend to be located on the outskirts of urban centres close to consumer markets.
Plants manufacturing items with longer shelf life, such as butter, milk powders, cheese and whey
powders, tend to be situated in rural areas closer to the milk supply. Most large processing plants
tend to specialise in a limited range of products. Exceptionally, however, large plants producing
a wide range of products are still common in Eastern Europe, a holdover from the former
centralized, supply-driven concept of the market.

As processing plants grow fewer and larger, they tend to acquire bigger, more automated
and more efficient equipment. While this technological tendency keeps manufacturing costs
lower, the need for long-distance transportation often increases the environmental impact.

Milk production is irregular, depending on cow biology. Producers must adjust the mix of
milk which is sold in liquid form vs. processed foods (such as butter and cheese) depending on
changing supply and demand.

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INDIA: WORLDS LARGEST MILK PRODUCER

India has become the world's No. 1 milk producing country, with output of 78 million
tonnes in 1999-2000.

United States, where the milk production is anticipated to grow only marginally at 71
million tonnes, occupied the top slot till 1997. In the year 1997, India's milk production was on
par with the U.S. at 71 million tonnes. The world milk production in 1998 at 557 million tonnes.
The annual rate of growth in milk production in India is between 5-6 per cent, against the world's
at 1 percent. The steep rise in the growth pattern has been attributed to a sustained expansion in
domestic demand, although per capita consumption is modest - at 70 kg of milk equivalent.

WORLDS TOP MILK PRODUCERS

COUNTRY 2008 2009 2010

USA 86,177,400 85,880,500 87,461,300
India 47,006,000 47825000 50,300,000
China 35,873,807 35,509,831 36,022,650

Russian Federation 32,110,700 32,325,800 31,895,100

Brazil 28,440,500 30007800 31,667,600

Germany 28,656,300 29,198,700 29,628,900
France 23,564,900 22,653,100 23,301,200
New Zealand 15,216,800 15,667,400 17,010,500
UK 13,719,000 13,236,500 13,960,000
Turkey 11,255,200 11,583,300 12,480,100
World 583,135,236 586,239,893 599,615,097

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MILK PRODUCTION

About 95% of world buffalo milk (45.3 million tonnes) is produced in Asia & Pacific,
while 64.4% is produced in India (FAO.1992) From 1950 to 1992 milk production in the world
increased by 4.26% The % of total bovines slaughtered; Total bovine slaughtered (%) World
17.1 to 17.4% or - 1.6% per annum India 15% per annum Asia 6.6% Increasing trend of buffalo
population in most of the Asian countries in Brazil and Italy Buffaloes found in the north
eastern states and the eastern coastal region of India & in China South east Asian countries e.g.
Philippines, Thailand, Malaysia, Vietnam, Srilanka, Burma, Laos, Kampuchea, Bangladesh etc.
have been classified as swamp buffaloes on the basis of their genetic constitution (2n=48) &
natural habitat. The breeds includes in these groups are Manda & Palakhemundi.

MILK COMPOSITION:

LIQUID
S.NO CONSTITUENTS BUFFALO COW GOAT
SKIMMEDMILK

1 Moisture (gm) 81.00 87.50 86.80 92.10

2 Protein (gm) 4.30 3.20 3.30 2.50

3 Fat (gm) 6.50 4.10 4.50 0.10

4 Minerals (gm) 0.80 0.80 0.80 0.70

5 Carbohydrates (gm) 5.00 4.40 4.60 4.60

6 Energy calories (kcal) 117.00 67.00 72.00 29.00

7 Calcium (mg) 210.00 120.00 170.00 120.00

8 Phosphorus (mg) 130.00 90.00 120.00 90.00

9 Iron (mg) 0.20 0.20 0.30 0.20

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BUFFALO MILK Vs COW MILK

No difference in nutritive value

There is practically no difference in the nutritive value and digestibility of milk and milk
products obtained from cow and buffalo milks.

Lower cholesterol content

Significantly, cholesterol content of buffalo milk is 0.65 mg/g as compared to the

corresponding value of 3.14 mg/g for cow milk.

More proteins

Animal bioassays have shown the Protein Efficiency Ratio (PER) value of buffalo milk
proteins to be 2.74 and that of cow milk as 2.49. It will be seen that buffalo milk has about 11.42
per cent higher protein than cow milk.

More important minerals

Buffalo milk is also superior to cow milk in terms of important minerals, namely calcium,
iron and phosphorus which are higher by 92 per cent, 37.7 per cent and 118 per cent
respectively than those present in cow milk.

More vitamin A

Buffalo metabolizes all the carotein into vitamin A, which is passed on to milk as such.

OPERATION OF THE DAIRY FARM

When it became necessary to milk larger numbers of cows, the cows would be brought to
a shed or barn that was set up with bails(stalls) where the cows could be confined while they
were milked. One person could milk more cows this way, as many as 20 for a skilled worker.
But having cows standing about in the yard and shed waiting to be milked is not good for the
cow, as she needs as much time in the paddock grazing as is possible. It is usual to restrict the
twice-daily milking to a maximum of an hour and a half each time. It makes no difference
whether one milks 10 or 1000 cows, the milking time should not exceed a total of about three
hours each day for any cow.

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 As herd sizes increased there was more need to have efficient milking machines, sheds,
milk-storage facilities (vats), bulk-milk transport and shed cleaning capabilities and the means of
getting cows from paddock to shed and back.

Farmers found that cows would abandon their grazing area and walk towards the milking
area when the time came for milking. This is not surprising as, in the flush of the milking season,
cows presumably get very uncomfortable with udders engorged with milk, and the place of relief
for them is the milking shed.

As herd numbers increased so did the problems of animal health. In New Zealand two
approaches to this problem have been used. The first was improved veterinary medicines (and
the government regulation of the medicines) that the farmer could use. The other was the
creation of veterinary clubs where groups of farmers would employ a veterinarian (vet) full-time
and share those services throughout the year. It was in the vet's interest to keep the animals
healthy and reduce the number of calls from farmers, rather than to ensure that the farmer needed
to call for service and pay regularly.

Most dairy farmers milk their cows with absolute regularity at a minimum of twice a day,
with some high-producing herds milking up to four times a day to lessen the weight of large
volumes of milk in the udder of the cow. This daily milking routine goes on for about 300 to 320
days per year that the cow stays in milk. Some small herds are milked once a day for about the
last 20 days of the production cycle but this is not usual for large herds. If a cow is left unmilked
just once she is likely to reduce milk-production almost immediately and the rest of the season
may see her dried off (giving no milk) and still consuming feed for no production. However,
once-a-day milking is now being practised more widely in New Zealand for profit and lifestyle
reasons. This is effective because the fall in milk yield is at least partially offset by labour and
cost savings from milking once per day. This compares to some intensive farm systems in
the United states that milk three or more times per day due to higher milk yields per cow and
lower marginal labor costs.

Farmers who are contracted to supply liquid milk for human consumption often have to
manage their herd so that the contracted number of cows are in milk the year round, or the
required minimum milk output is maintained. This is done by mating cows outside their natural

13
mating time so that the period when each cow in the herd is giving maximum production is in
rotation throughout the year.

Northern hemisphere farmers who keep cows in barns almost all the year usually manage
their herds to give continuous production of milk so that they get paid all year round. In the
southern hemisphere the cooperative dairying systems allow for two months on no productivity
because their systems are designed to take advantage of maximum grass and milk production in
the spring and because the milk processing plants pay bonuses in the dry (winter) season to carry
the farmers through the mid-winter break from milking. It also means that cows have a rest from
milk production when they are most heavily pregnant. Some year-round milk farms are penalised
financially for over-production at any time in the year by being unable to sell their
overproduction at current prices.

1.2 COMPANY PROFILE

Amirthaa Dairy Private Limited established in the year 2015. We are leading
Manufacturer and Supplier of Skimmed Milk Powder, Whole Milk Powder. Being a client
focused firm, we are occupied in providing best class Dairy Products. Offered products are the
perfect substitute of natural milk. These products are free from lumps and are easily soluble in
worm as well as normal water. Apart from this, we provide these products in excellent packaging
material at most reasonable rates.

Being known amongst client centric firms, we are engaged in offering a comprehensive
range of Whole Milk Powder. The product we offer to the patrons is most suitable for use by
people on a low calorie and high protein diet. Customers like our product for its high nutritional
value and longer shelf life.

Infrastructure Facilities

Company occupied 1 acre area.

Mission

Hectare's mission is to build a world class real estate development company with the
highest standards of profesionalism, ethics and customer service.

14
 To be a dynamic growth oriented organization where individuals and work-groups are
highly motivated and empowered to take up challenges and aim towards excellence in their
pursuit.

To be a professionally-managed company, which constantly reinvent itself to Attain the

global benchmarks.

To always deliver ahead of time, with uncompromising quality and safety standards.

To achieve our objectives in an environment of fairness, honesty and courtesy towards

our clients, employees, vendors and society at large.

Vision

To become a diversified regional real estate holding company, specialized in real estate
and related activities in locations where the company identifies an advantage and to build a
world-class real estate concepts.

Values

Customer Delight
Business with Ethics
Pursuit of Excellence
Teamwork
Leadership by Example
Integrity and Transparency
Concern for all stakeholders
Honesty & Fairness

Motto

Implementation of eco-friendly alternatives on construction activities.

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Projects

Hectare presents to you its range of properties that stand the test of time and vagaries of
nature. We firmly believe in the need for precision and quality that commences from
conceptualization and continues for decades. Hectare construction solutions are delivered after
careful synthesis with client requirements. There is complete transparency in our dealings and
documents with no room for compromises of any sort.Propelled by the strong impetus in
delivering before time, the organization adheres to statutory norms and builds green homes for
an environment that is healthy and beautiful. Hectare holds the responsibility of preserving
water, optimizing energy and producing less hazardous waste from the stage of inception to
completion.

Dairy Products

Skimmed Milk Powder

Specification:

Moisture%- 4.01
Fat %- 0.72
Protein%(dry Basis)- 34.98
Protein%(as Is) - 33.54
Ash%- 7.74
Titratable Acidity%- 1.6
Particle Size(mesh 10)- 100% Passes
Powder Color(yellowness Index)- 28.71
Total Bacterial Count (cfu/gm)- 270
Salmonella Sp- Absent
E.coli- Absent
Staphylococcus Aureus- Absent
Yeast(cfu/gm)- 10
Mould(cfu/gm)- 10
Coliforms(cfu/gm)- 10

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Whole Milk Powder

Features:

Rich in proteins

Healthy

Delightful taste

Skimmed Milk Powder (25 KG)

Features:

Wide usage

Hygienic

Rich taste

Whole Milk Powder (25 KG)

Features :

High purity

Effectiveness

Accurate composition

Managing Director : Dhayalan

Director : Mohanasundaram Aravind Kumar

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FACT SHEET

Year of Establishment : 2015

Legal Status of Firm : Private Limited Company

Nature of Business : Manufacturer

Number of Employees : 600 People

Turnover : Rs. 100 - 500 Crore ( or US$ 20 Mn - 100 Mn Approx.)

Address

No. 34/84, Jeevanantham Street, Kollampalayam

Erode - 638002

Tamil Nadu, India

18
1.3 ORGANIZATION CHART

Managing Director

General Manager

Production Finance Purchase Sales HR Manager

Manager Manager Manager Manager

Supervisor Accountant Assistants Supervisor Supervisor

e

Workers Cashier Workers Workers Workers

19
 CHAPTER II
FUNCTIONAL AREAS IN THE COMPANY

2.1 PRODUCTION DEPARTMENT

The fresh milk is brought to the reception which is tested for PNF and Fat. After the test,
the milk is graded. If the milk has gone sour it is sent for curd processing. Then the milk is
pumped into the SILO (tanks) for storage, throughout temperature of 4 o C is maintained. Then
from the SILO the milk is sent for processing.

Pasteurization
Homogenization
HOMOGENIZATION:

It is a process of beating all particles of milk together and making it homogeneous. This
can be done by applying a heavy pressure of 1180kg/m^3.

PASTEURIZATION:

The heating of every particle of milk or milk product to a specific temperature for a
specified period of time without allowing recontamination of that milk product during the heat
treatment process and then recool it to 4degree

DAIRY UNIT:

Normal milk contains 4.5% of fat, 8.5% of solids and rest of 85% water.Sakthi milk
industries process up to 1.8 lakhs litres to 4 lakhs milk daily. They process the milk in four
different varieties. They are

Special

Super

Select

Slim

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 SPECIAL:

The variety special contains 4.5% fat homogenate milk. It said to be standardized since it
contains 4.5% fat in it.

SUPER;

The variety super contains 3% fat and the rest 1% which is available in the natural milk is
removed from it. It is also homogenate.

SELECT:

The variety select contains 3%fat and it is non homogeneous.

SLIM:

This variety slim contains only 1.5% fat and all the rest of the fat is removed which will
be later used for ghee preparation. This variety is specially made for the old age people and the
patients who have to consume less fat. It is also homogenated milk.

CHILLER:

The milk is being bought from various places and stored in containers. The chillers will
maintain the temperature of milk from 4 degrees Celsius. This will kill some of the bacteria
which can be killed in low temperature.

STANDARD MILK:

Milk is said to be standardized if it contains 4.5% of fat. Natural milk gets in the south
Indian region normally contains 4.5% of fat. In order to produce the varieties super, select,
slim, some amount of fat has to be removed. This done using the principal of centrifugal force.

The milk which contains 4.5% fat, and through the process homogenization and
pasteurization is called STANDARDIZED HOMOGENEOUS PASTEURIZED MILK.

21
 PRODUCTION PROCESS

MILK RECEPTION IN CANS

SAMPLE MILK FOR TESTING 1

WEIGHING THE SAMPLE

FILTRATION

CHILL WATER INLET CHILLING CHILLWATER OUTLET

STORAGE
SAMPLE TESTING 2
PRODUCT SAMPLING

STANDARDISATION

REGENERATION

CREAM SEPERATION

REGENERATION

HOT WATER INLET HOMOGENIZATION HOT WATER OUTLET

CHILLING

PROCESSED MILK STORAGE

PACKING SAMPLE TESTING 3

COLD STORAGE

DESPATCH

From the Reception the milk is stored in the large tanks known as the SILO. The SILO
can hold nearly 100kl. The milk is then sent for Standardization, Homogenization, and
Pasteurization.

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MILK PROCESSING

Standardization:

Standardization is the process of manipulating the constituents of milk by addition

and deletion of cream and SMP (skim milk powder). It refers to adjustment increasing or
decreasing the fat and SNF percentages to desired value, so to conform as to get the desired
requirements.

Homogenization:

It is nothing but a process of beating all particles of milk together and making it
homogenous. The machine used for this purpose is called homogenizer. This would make the
milk thicker. This is done by applying a high pressure of 1180kg/m^3. No cream line is formed
on the milk after homogenization or butter granules cannot be produced from churning.

Cream separation:

At high speed (7100-7400 rpm) low dense fat globules move to the center and the
SKIM MILK to periphery the cream is sent to the ghee plant for butter or again mixed with
process line for pasteurization. Skim milk is processed and sent to powder plant.

Pasteurization:

Heating of milk to 72C to 76C temperature for a period of 15 to 20 seconds and

then immediately cooling it to 4 C. By this process the harmful bacterias such as pathogens are
removed and it doesnt allow recontamination of milk.

Storage:

To ensure uniform supply of the packing machines milk is stored in SILOS.

Packing:

Packing film made by LDPE is sterilized by UV rays and milk is packed

automatically. The filled pouches are arranged in crates and sent to the cold room. Samples are

23
taken for testing the keeping quality, strength of pouch and to check whether it is
microbiologically safe.

Dispatch:

Pouches arranged in crates are dispatched to the consumers in insulated containers

vehicles as per the orders collected.

POWDER PLANT

In general milk contains 4.5% of fat and 8.25% of SNF and 87% water. The
powder must contain 0% fat. So the fat is completely removed by centrifugal method, where the
fat is completely separated from milk. This fat is used for preparing butter and ghee. Now the
milk contains only SNF and water. The milk is now passed into long cylinders called
CALANDRIA and sent into number of small pipes inside the Vapour seperators. There are four
vapour seperators all commonly connected to a vacuum pump. A vacuum is connected to create
vacuum in the vapour separators, so that the water which boils at 100C would boil at 48C by
itself in the vacuum. By creating vacuum, the fuel used to evaporate water can be up to 50% of
its required quantity.

Steam from the boiler is used to heat the water in the vacuumised vapour
seperators. The water is removed from milk as it becomes vapour at 48C. now, the milk with
only the SNF is sent to the drier, where the milk is sprayed from the top and the hot air blown at
the sides turns the milk into powder form. This milk powder is sent directly to the packing
section.

MILK POWDER:

Milk powder is mostly prepared when there is excess supply of milk and stored. It
is marketed in packets in the brand name Amirthaa milk Powder. Amirthaa milk industry
provides processed powder to other industries that do not have a powder plant, and get the
processing charge for it.

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 Advertisement of all the products of ABT Dairy Industry is through Newspapers.
The average cost of advertisement is around 1,00,000 per month. Advertisement for the products
is more during the festival season to attract more customers.

Amirthaa has created a huge brand name among its customers because of its
quality, quantity and price of the product. There are many competitors for the product like Amul,
Hatsun, Cavins milk. But the success of their product is by ability to maintain farm to home
freshness which is their objective which paves way to keep up with its competitors. The
company has a plan to extend its market to all over India

Milk powder production

The dairy whitener is the product obtained from milk by removing water by heating it up or by
other suitable means. By this procedure, we obtain a solid containing 3.5% or less moisture. Two
types of milk is used for drying whole milk and skimmed milk. The powder obtained from whole
milk is called whole milk powder and powder obtained from skimmed milk is called skimmed
milk powder.
Process Description

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2.2 QUALITY CONTROL DEPARTMENT

The quality of the milk gets deteriorated during the process of handling of till it is
received at the dairy dock. The milk gets contaminated with harmful bacteria, pesticides,
veterinary drugs, antibiotic residue, dirt, flies, hair, etc.., in the course of handling. The major
contributing factor are the fodder, health of the animal, dirty environment, unclean cattle shed,
milker, utensils, poor quality of water used for cleaning etc. It is estimated that contamination up
to 60% takes place at the producers level and collection centres level.

2.3 PURCHASE DEPARTMENT

We can purchase our material in the stores. In stores we maintain:

Stores monthly work closing 1st day.

Casual labour salary payment 3rd day.

PF register updating 5th day.

Central exercise 10th day.

Attendance marketing daily.

Stores purchase material computer feeding(GRN).

Material purchase.

Stores issues feeing.

Minimum stock verification.

Purchasing Management:
Purchasing management covers a wide range of activities which includes some of the
following
Purchasing Procedures
Vendor Selection
Strategic Purchasing
Vendor Participation

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 Purchasing management is about working with key suppliers to make it easier to do business
by developing vendor partnerships.

Their purchasing management insures the best possible cost, quality and on time deliveries.
Purchasing management might also include asking suppliers to participate I marketplace
reviews, analyzing product failures, alternative designs, asking vendors to share information and
expertise, just to name a few.

Purchasing management maximizes vendor participation and minimizes their companys

expense in ordering, receiving inspecting and maintaining the inventory.

Inventory Reduction:
Inventory reduction is about eliminating excess inventory, improving inventory turn
rates, increasing inventory turnover, and meeting on time delivery. Excess inventory ties up
money and needs to be reduced in order to free up cash for investment in revenue-growth
activities.

2.4 HR DEPARTMENT

Human resource management is the process of recruiting, selecting, procuring, training of

human resource. Every organization should need the right person for the right place for which
they are giving attraction to many candidates. After selecting the right person for the job the
training is provided by the superiors, so that he/she become aware about the job and can handle
this/her job effectively and efficiently. The human resources in an invaluable asset of any
organization and in order to take a proper care of employees every organization should provide
welfare schemes to their employees, identifying the hazardous areas, maintaining the plant and
machinery and so on.

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Company provides welfare to their employees to keep their motivation levels high. They also
identify areas of the machine which can cause injury or illness and maintain their plant and
machinery as well.

Welfare schemes:
The employee welfare schemes are classified into two categories viz., statutory and non-
statutory welfare schemes the statutory welfare schemes of Amirthaa milk industry include the
following provisions:

(A)STATUTORY WELFARE SCHEME:

Drinking Water:
At the working place safe hygienic drinking water in provided.

Facilities For Sitting:

Suitable seating arrangements are provided for the employees.

First Aid Applicants:

First aid appliances are provided and these are readily assessable so that in case any minor
accident initial medication can be provided to the needed employee.

Latrines and Urinals:

A sufficient of latrines and urinals are provided in the office and factory
premises and are maintained in a neat and clean condition.

Canteen Facilities:
They have canteens and mess halls which provide hygienic and nutritious
food to the employees. They provide free lunch to their employees as also dinner for the night
shift workers.

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 Lighting:
Proper and sufficient lights are provided for employees so that they can work
safely during the nights shifts.

Washing Places:
Adequate washing places such as bathrooms, wash basins with tap and tap on the stand pipe
are provided in the vicinity of the work places.

Changing Rooms:
Adequate changing rooms are provided for works to change their cloth in the factory
are and office premises. Adequate lockers are also provided to the workers to keep their
clothes and belongings.

Rest Rooms:
Adequate numbers of restrooms are provided to the works with provisions of water supply,
wash basins, toilets bath room, etc.
(B) NON STATUTORY SCHEMES:

Personal Health Care (Regular Medical Check-Up):

They provide the facility for extensive health check-up for our employees.

Flexi-Time:
The main objective of the flextime policy is to provide opportunity to
employees to work with flexible working schedules. Flexible work schedules are
initiated by employees and approved by management to meet business commitments
while supporting employee personal life needs.

Employee Assistance Programs:

Various assistant programs are arranged like external counseling service so that

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 employees or members of their immediate family can get counseling on various
matters.

Harassment Policy:
To protect an employee from harassment of any kind, guidelines are provided
for proper action and also for protecting the aggrieved employee.

Maternity And Adoption Leave:

Employee can avail maternity leaves. Paternity leave policies have also been
introduced.

Medi-Claim Insurance Scheme:

They offer insurance adequate insurance coverage of employees for expenses
related to hospitalization due to illness, disease or injury or pregnancy.

Employee Referral Scheme:

Under this scheme employee refer friends and relatives for employment in
the organization.

Besides these, the below mentioned comprise their employee welfare scheme:

Seven days working hours a week.

Subsidies for marriage, funerals, child birth and hospitalization.
Scholarships for employees and their children
Bonus and company stock-purchase programs.
A comprehensive provident fund scheme and retirement plan.
Provide subsidized domestic and overseas travel plans for employees.

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2.5 MAINTENANCE DEPARTMENT

They have employed about eight permanent servicemen who take of all their
machinery and equipment. All of their machinery and equipment are properly checked on regular
intervals in order to ascertain any faults. This has helped in reducing abrupt and long
breakdowns. The machinery and the equipment at their plants are properly oiled and greased in
order to reduce their wear and tear.

The conveyor belts of machines are also changes at regular intervals in order to avoid
unnecessary breakdowns. Further they also have technical collaboration with the supplier of the
machinery where from we get necessary spare parts. They also render technical support in case
our in-house service team in not able to service some equipment or a machine. To attend to this
they have complete systems in place for plant maintenance.

This system includes the following elements:

(a) ALLOCATION OF RESPONSIBILITIES:

They allocate appropriate responsibilities for people who are associated with the
inspection and maintenance work (including managers. supervisors as well as people who
undertake inspection and maintenance). They ensure that people fully understand their
responsibilities.

(b)PLANT REGISTER:
They maintain an up-to-date register of the specific items of plant in the workplace
requiring a preventative maintenance program.

(c)WORK REQUIREMENT:
After determining the appropriate frequency and type of inspection and maintenance
required for each item of plant are recorded on the register. To identify the areas they refer to
the manufacturers instruction; what is recommended in the relevant published technical
standards.

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(d)PROCEDURE DEVELOPMENT:
They develop procedures for the inspection and maintenance work (including what parts
of the plant need to be inspected and how that plant should be safely isolated, locked out and
tagged during inspection and maintenance) using the relevant information provided by the
manufacturer as the basis. Then we carry out a job safety analysis to identify what hazards
(including manual handling) are associated with each step of the inspection and maintenance
procedures and the measures required addressing the hazards. They have also developed.
Procedures for the reporting of faults, damages or defects of plant and for addressing the
reported deficiencies.

(e)RESOURCE ACQUISITION:
They identify the skills required by people who carry out inspection and maintenance and
where those skills can be obtained and engage the people who have the appropriate skills to carry
out the inspection and maintenance.

(f)REPLACEMENT OF PARTS:
They maintain an effective system for ensuring that any replacement of parts of the plant
that have an impact of health and safety is of the design and material at least as good as the
original part.

(g)SAFETY CONFIRMATION:
They maintain an effective system for confirming that the plant is safe to operate before
returning it to use after being cleaned, inspected, services or repaired.

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 CHAPTER III
CONCULSION

At the end of training at Amirthaa Dairy Private Limited, Erode, I include that this
training helps me to gain more practical exposure. The training I undergone helps me to learn
about the policies following in the organizations, helps me to known about the department
framework.

While concluding this report I would to thank once again the manager and all others
staffs of Amirthaa Dairy Private Limited for their immense help guidance in making my
institutional training projects, a grant success.

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 BIBLIOGRAPHY

1) ASWATHAPPA.K Human Resource and Personnel management

i. Tata Mc. Graw Hill Publishing co. Ltd., 2006

2) Kotler Philip Marketing Management

i. Pretice hall of india pvt., 2004

3) Pandey I.M financial management

4) Vikaspublishing house pvt.ltd.,2001

5) www.avtnaturalproducts.com

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