BANAS DAIRY REPORT PRESENTATION PPT 2011

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i Presentation on In-plant Training At “Banas D airy” Banaskantha District Co-operative Milk P roducer Union Ltd. Palanpur-385001 Presented By Dinesh A Chaudhary B.Tech (Dairy & Food Technology) 7 Th Semester 05-003-2008 1

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3 Introduction 3 3 Banas Dairy is located at the distance of 4 km from Palanpur , which is headquarter of Banaskantha district . Banaskantha district lies between 23.5 0 to 24.23 0 North Latitudes and 70 0 to 72.3 0 ­ East longitude The district of Banaskantha lies closely to the south of Rajasthan , covered by Aravali Hills in the East, the desert of Kutch in the West and North-West .

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Intro. Continue……… 4 4 A Total geographical area of the Banaskantha district is 12248 square Km of which 72% is cultivable while 12% land is irrigated by tube wells canals, etc. The area covered under forest is only sq.Km.Of total 20.99 Lac livestock population- 8 .54 Lac Cattle and 12.45 Lac Buffalo as per the cattle census 2011 . The total land acquired by Banas Dairy is 122 acres .

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5 Banas Dairy markets its products under a very powerful brand name “ AMUL ”, “ SAGAR” & “ BANAS ” . It produces a wide variety of products like Milk, Milk Powder, Ghee, Ice-cream, Amul butter and Amul Cool ,Cheese, Paneer, buttermilk , Long life milk, Banas Tea etc

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6 Bankers

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Location Chart of Banas Dairy

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9 Location chart……

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13 Member of GCMMF Union

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14 Continue.......

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16 History & Development Late Shri Galbabhai Nanji bhai Patel who was founder chairman of banas dairy . He started dairy by help of eight village level milk societies in Vadgam and Palanpur Taluka . “ BANAS DAIRY ” was registered under co-operative Act on 31 st January 1969 as “Banskantha district co-operative milk producers union limited” Palanpur

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17 The foundation stone laid down by late Sheri Galbabhai Nanji Patel on 14 th January 1971 at 122 acres land acquired near Jagana village in order to set up a dairy plant under the Operation Flood Program launched by NDDB . ON 5 th February 1971 (Day of Vasant Panchmi), A dairy started functioning at the same place with handing capacity of 1.51 Lac liters of milk. This dairy plant was expanded later on with processing capacity of 4 Lac liters milk per day. History Continue….

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18 History Continue….

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19 History Continue….

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20 History Continue….

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21 History Continue….

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22 History Continue….

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23 History Continue….

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24 The Banas dairy has manufacturing capacity of 110 TPD Milk Powder , 40 TPD ,Table Butter , 8 TPD Ghee , 1 LL of Milk packing , 20,000 liters of Ice-cream & 6000 liters per hour of UHT Milk . Banas dairy also started selling tea under the brand name “Banas Tea”. It has recently started an Internet project “ Chirag ” , in which it provides Internet connection to the rural areas on subsidized rates. History Continue….

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25 Organizing Team

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26 Org. Team Continue .............

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27 27 Org. Team Continue .............

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28 28 Organizing Team

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29 Banas Dairy Organizational structure

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MALTED MILK FOOD 30 30

Nutritional Composition of Nutramul : 

Nutritional Composition of Nutramul Fat : 6.0 % Carbohydrates : 70 % Moisture : 4 % Protein : 11.5 % Cocoa powder : 8% Total ash : 5% Max Acid insoluble ash : 0.1% Max Solubility : 90% Min Total bacterial count (cfu/g) : 50,000 Max Coliform count in 1 g powder : 10 Max 31 31

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32 Raw materials Kettle-I Addition of water, cocoa powder, malt extract, SBC Cooking 75±5 0 C for 1 hr Kettle-II Addition of water, milk powder, salt, vanilla Cooking 95±5 0 C for 1 hr . Addition of sugar, caramel, lecithin, reprocess powder. Filtration (after adding heated mix from Kettle-I and II in tank) Process Flowchart Conti..

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33 Vacuum Evaporator (700-740 mmHg) 55-60 0 C, T.S. 86% Collection in vats Spreading in Trays Cooling (room temperature) Vacuum drying 70-80 0 C,4h Vacuum= 29Kg/cm 2 Magnet Grinding/scraping/sifting Nutramul Powder Bag/Drum filling (Bulk packing) Conti..

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34 Product Conveyor Refill packing Consumer packing Conveyor Magnet Balance Magnet Re-processing to kettle -1 Balance Bottle packing Storage

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VACUUM DRYER Maker: CHEMICAL VESSEL FABRICATORS LTD., KOLKATA Drying temperature : 75 0 C Steam pressure : 8.5 bars Vacuum pressure : 29 kg/cm 2 Number of ovens : 12 Tray holding capacity of each oven : 45 Time taken for drying : 4 h 35

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Process Activity Monitoring Accptance criteria Cooking Temp. 95±5 0 C Evaporation Temp. < 60 0 C Drying Temperature Vacuum Pressure 70 – 80 0 C 25-30 kg/cm 2 Grinding Magnet Sensitivity Product Moisture < 4 % Packing Weight 500 ± 10g 36 PROCESS MONITORING

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CHOCOLATE MANUFACTURING UNIT 37

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Chocolate as per PFA: “Chocolate means a homogeneous product obtained by an adequate process of manufacture from a mixture of one or more of the ingredients mainly cocoa beans ,cocoa nibs, cocoa mass , cocoa cake including fat refused cocoa powder with or without addition of sugar, cocoa butter, milk solids including milk fats and non prohibited flavoring agents. The chocolate shall not contain any vegetable fat other than cocoa butter.” 38

Product Details: 

Product Details Product name : Amul Chocolate. Pack size : 30/35 g wrapped in aluminum gold foil and sleeved. : 15 g wrapped in BOPP along with stiffener at bottom. Product name : Almond bar Pack size : 35 g wrapped in BOPP along with stiffener at bottom. Rest … 264 g chocozoo in tins. 500 g chochozoo in plastic tub. 500 g slabs in 10 box (for Institutional sales). Tins of 15 & 20 kg (for Institutional sales). 39

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Usage : 1. Consumed as such. 2.Consumed as ingredient in ice creams and bakery products. Intended Use : The product is intended for consumption by the general population, which will include children and the elderly. Shelf life : Best before 12 months when stored at 15 0 C for 500g slabs, 30/35 g, and 15g. Best before 12 months from packaging if stored under cool and dry place for tins of 15 and 20 kg (Being Institutional product). 40

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41 Raw materials Weighing silo Mixing Refining Conching (at 55 o C /18-24 hrs) Stored in tanks Tempering (1st Stage: 28 0 C to 29 0 C, 2nd stage: 30 to 31 0 C) FLOW DIAGRAM Conti..

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42 Moulding Machine Packaging at 21 0 Cand storage at 15 0 C Vibrator (For even spreading of chocolate within the mould) Demoulding Cooling/Hardening (8 to 10 0 C for 20-22 min) Tempering (1st Stage: 28 0 C to 29 0 C, 2nd stage: 30 to 31 0 C)

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REFINING: Machine Make: CARLE AND MONTANARI, MILANO (ITALY) Temperature and pressure of rolls are adjusted for the fineness of the refined mass (upto 20 microns). Five rollers are there each having different pressure. 1 st roller : 2 to 3 kg/cm 2 2 nd 2 nd roller : 3 to 4 kg/cm 2 3 rd roller : 4 to 5 kg/cm 2 4 th roller : 5 kg/cm 2 5 th roller : 2 kg/cm 2. Rollers rotate in opposite direction & works on hydro pneumatic system. Cold water is circulated in all cylinders to maintain temperature between 15- 18˚C. At the 5 th roller scrapping knife is situated so that refined chocolate mass is continuously scrapped and conveyed it to the concher through steel conveyor. Capacity : 300 kg/h 43

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CONCHING: Machine Make: CARLE AND MONTANARI, MILANO (ITALY) Temperature Range: 0-120 o C Capacity: Conche1 :1500 kg/ 20 h Conche2 :1500 kg/ 20 h Conche3 :3000 kg/ 20 h Advantages: Flavor development & texture change. Elimination of bitterness & volatile compounds. Layer of fat covers the ground coco, thus changes the flow characteristics. 44

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45 TEMPERING: Machine Make: CARLE AND MONTANARI, MILANO (ITALY) Advantages: 1) Imparts flavors in final chocolate. 2)Provides desired flow properties for proper deposition in moulds that is increases thickness of paste. 3) Provides shrinkage for demoulding . 4) Provides high melting point. 5)Provides glossy and attractive finishing to chocolate.

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HIGH PROTEIN FOOD 46

PRODUCT DETAIL: 

PRODUCT DETAIL Product name: Amul Munch Time/ Munch Time Minis. Ingredients: Cereals flours, Sugar, Vegetable Oils and Flavor. Pack size: 20 g/ 40 g/ 250 g & 500 g in printed laminates. Usage: Consumed as such. Intended use: For general populations that includes elders and children. Shelf life: Best before 4 months from the date of packaging when stored at cool & dry place. Flavours – 1. Magic masala 2. Pickup masala 3. Podina masala 4 . Tomato masala 47

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48 Raw material from storage Sieving Weighing and Batch making Dumping Conveying Cooking by Extrusion(M.C 8-16%) Preconditioning(M.C 15-25%) Mixing Conveying Spicing(20rpm) Drying by Wenger Dryer(M.C 2%) Collection in bags Storage Collection in bags Packaging (Nitrogen Flushing) Dispatch FLOW DIAGRAM

Extrusion Details: 

Extrusion Details Speed of screw in preconditiner - 46rpm Extrusion pressure - 40psi Temperature during extrusion - >90 ⁰ C Speed of knife - 7-8rpm Die diameter - 3mm, 6holes(minis),12holes(munch) Drying temp and time - 103 ⁰ C, 20min 49

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Process Activity Monitoring Acceptance Criteria Drying Drier temp. Minimum 100 0 C Packing Weight checking (Net weight) Sealing and packing of RTE and Munch Time Min 310 g for 9 pouches of 30 g of Munch Time & 220g for 9 pouches of 20g Munch Time. No Packing defect Product Storage To be kept on pallets Temp. of store Good condition of pallets Ambient temp. 50 PROCESS MONITORING

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BREAD SPREAD UNIT 51

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FAT SPREAD BY PFA: “A Product in the form of water in oil emulsion, of an aqueous phase and a fat phase on an edible oils and fats, excluding animal body fats. The individual oil and fat used in the spread shall conform to the respective standards prescribed by the rules.” Fat spread can be classified into the following three groups: 1. Milk fat spread : Fat content will be exclusively milk fat 2. Mixed fat spread : Fat content will be a mixture of milk fat with any one or more of hydrogenated, unhydrogenated refined edible vegetable oils or interesterified fat. 3.Vegetable fat spread : Fat content will be a mixture of any two or more of hydrogenated, unhydrogenated refined vegetable oils or interesterified fat. 52

Product Details: 

Product Details Product name : Amul Lite & Delicious . Ingredients : Unhydrogenated vegetable oil, common salt, skimmed milk powder, emulsifiers, permitted class 2 preservatives, sequesterant & antioxidants, vitamin A not less than 30 IU/g and vitamin D 2 IU/g . Net weight : 8g, 100g, 200g, 500g. Usage : 1. Consumed with bread and bun. 2. Used in Bakery. Intended Use : The product is intended for consumption by the general population, which will include children and the elderly. Shelf life : Best before six months when stored at 10 0 C or below. 53

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54 FAT PHASE Emulsifier Filtration Oil tanker Dumping Water Dumping W. Butter AQUEOUS PHASE Raw Material Oil Storage Tank Aqueous Phase Mixing Tank Starch, SMP, Salt Filtration Emulsifier Mixing Mixing, heating in HSBT (CP 1) Pasteurization (CCP 1) Batch Weigher Tank FLOW DIAGRAM

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55 Balance Tank Transferring to IBT(55 0 C) Mixing Smoothening in B-unit(350rpm) Cooling In A unit(25-30 0 C) Triplex Pump Packing machine Re-melt unit From Circulation Cups, Al foil & lids Dispatch Cold storage (CP 2) pH of Emulsion (5.2-5.6)(CCP 2) Additive addition (Citric Acid, Potassium Sorbate, Color, Flavor, Antioxidants Rework from packaging Dumping

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Process Activity Monitoring Amullite ( Accptance criteria) Delicious ( Accptance criteria) Fat phase heating Temp. 75±5 0 C 75±5 0 C Pasteurization of Aqueous Phase Temp. Time 75±5 0 C 30 min 75±5 0 C 30 min Standardization of Emulsion (1)pH (2)Moisture% (3)Fat% (4)Salt% 5.2 – 5.6 37.8 – 38.0 58 – 59 1.8 – 2.0 5.2 – 5.6 12 – 16 80 – 83 2.0 – 2.5 Packing of Bread spread Hygienic handling of bread. Paking integrity No packing defects No packing defects Product Storage Temp. of cold storage Below 10 0 C Below 10 0 C 56 PROCESS MONITORING

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VOTATOR: It is an agitated holding unit consisting of a tube, in which a Motorized shaft with agitating pins is there which revolves when under operation, so it can deliver soft products to tubs or bulk container. It has high efficiency of the heat transfer which results in a high rate of chilling and rapid formation of crystals. Complete exclusion of air and moisture from the product to be chilled is possible. Uniformity of product due to complete control over materials, temperature and pressures. It is a closed system thus prevents product from exposing to atmosphere & prevents refrigeration losses by radiation. 57

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Bakery Unit 58

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Different Methods of Bread Manufacturing: Conventionally there are 4 method of bread preparation. They are as follows. Straight Dough Method Sponge and Dough Method Salt Delayed Method No Dough Time Method 59

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60 Selection of Raw Material Formulation & weighing Mixing Bulk fermentation-1 Knock back Bulk fermentation-2 Dividing Rounding Intermediate proofing Molding, greasing & panning Final proofing Baking De-panning Cooling Slicing & packing Storage PROCESS FLOW CHART FOR BREAD

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SPIRAL MIXER It has a spiral shaped arm with arrangement of dual speed (Low and High) with automatic and manual controlling. It has a SS bowl which can be kept stationary or rotary. 1. Capacity of Flour 30 kg. 2. Capacity of Dough 50 kg. ROUNDER It basically consist of an external or internal revolving surface against which the freshly divided dough piece is held by a spiral track or trough. As the surface revolves, it carries the irregular shaped dough piece upward in the spiral rounding trough. Rounding motion results in uniform rounded dough ball with a thin, smooth and dense skin . 61

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MOULDER Two sets of rolling wheels made of Teflon. Dough Capacity is 30-400 g. OVEN The heart of bakery. Consists of a vertical baking chamber into which a special rack carrying 100 trays of product is wheeled. The rack rests on a turn table that rotates & thereby exposes the product to uniform convection heating. They are PLC controlled nowadays . Capacity : For Bread 120 loafs/batch (400 g.) 62

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PROCESS MONITORING 63 Process Activity Monitoring Bread Bulk Fermentation-1 Time, Temperature 90 min , 27°C Bulk Fermentation-2 Time, Temperature 30 min , 27°C Intermediate Proofing Time, RH, temperature 20 min, 75%, 27°C Final proofing Time, RH, temperature 55 min, 85% , 37°C Baking Temperature, time 220-240 °C, 25-30 min Cooling Time, temperature 120- 150 min, 25-27°C

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64 QUALITY ASSURANCE LABORATORY

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Quality is all those planned and systematic action necessary to provide adequate confidence that a product or service will satisfy given request for quality. The following test performed to monitoring measurement of products, from each unit. Incoming material In process product Finished product Microbial testing of finish product . 65 QUALITY ASSURANCE LABORATORY

Raw material analysis: 

Raw material analysis Sr. no. Raw material In house analysis 1 Cocoa powder Fat%, Moisture%, Ash(on DM)% SPC,Y & M per g,Coli per g 2 Sugar Moisture, Foreign particles 3 Malt extract Color, Acidity %, TS, Sedimentation, Protein dm% 4 Caramel TS, Specific Gravity, Identify tests 5 Emulsifier Moisture, Acid value, Benzene Insoluble 6 Acidity regulator Foreign Particle, Identification test 7 Milk powder Moisture, Physical Appearance Taste & flavor 8 Pure salt Foreign Particles and physical condition 9 Flavor (vanillin powder) Appearance, Color, Texture 10 Liquid flavor (liquid flavor) Appearance, Test certificate 66 Malted Milk Food

Finished Product Analysis: 

Finished Product Analysis Sr no. Process Parameters 1 Finished product. Organoleptic Quality Reconstitution, Burnt particles, Iron particles, Milk coagulation Moisture - NMT 4% by wt , Protein - NLT 11.5% by wt. Fat- NLT 6.0% by wt. Ash - NMT 5% by wt Solubility - NLT 90% Cocoa powder - NLT 5.0% 2 Microbiological Analysis SPC- 50000 cfu per gram Coli- 10 No.per gram 3 Nutramul packing Heat sealing, Printing, Weight 4 Nutramul Slurry pH- 6.6-6.7 Total Solids- 72-77 67

Chocolate : 

Chocolate Sr. no Raw material parameters 1 Cocoa bean Moisture%, Infestation%, Mouldy% 2 Cocoa powder As in MMF 3 Sugar As in MMF 4 Choco whip Moisture%, Color, Solubility, Ash% 5 Emulsifier – Lecithin As in MMF 6 Milk Powder As in MMF 7 Liquid Flavors(Vanilla liquid) Appearance, Test certificate 8 Almond Taste, Infestation, Foreign matter, Size 9 Raisin Taste, Infestation, Foreign matter,Size 10 Vegetable fat MP, FFA% , PV% 11 Liquid glucose pH, TS 12 Cocoa butter FFA 13 Maltitol Moisture, TC 68 Raw Material Analysis

In Process Analysis: 

In Process Analysis Sr. no Process Parameters 1. Roasting Moisture of beans 2. Winnowing Husk% in composite sample 3. MPH Cocoa liquor residue% 4. Cocoa Powder Grinding Cocoa liquor residue% 5. Refining Particle size(micron), Sugar, Cocoa 6. Moulding F/N % in 35 g fruit & nut chocolate 7. Enrobing % chocolate coating 8. Packing All packing parameters such as weight, heat sealing, declarations etc. 69

Finished Product Analysis: 

Finished Product Analysis 70 Sr. No. Process Parameter 1. Conch sample Moisture%, Flavor & taste

Bread Spread : 

Bread Spread Raw material analysis 71 Sr. No. Raw material In house Analytical Parameter 1. Veg. Oils Slip melt point, FFA%, OT 2. White Butter OT, Moisture%, Physical observation 3. Milk Powder As in MMF 4. Salt As in MMF 5. Starch Colour , Moisture%, Iodine test 6. Potassium sorbate Solubility 7. Citric Acid Appearance 8. Lecithin As in MMF 9. Domodan MP, Acid value 10. TBHQ Colour , Solubility 11. Colour Colour -red, Colour -yellow 12. Vit . A & D Test certificate 13. Liquid flavors Appearance, Test certificate

In Process Analysis: 

In Process Analysis Sr. No. Process Parameter 1. Standardization Moisture, Salt, pH, Starch test 2. Packing Moisture ,Fat, Salt, Color, OT 3. Packing line Packing parameters such as weight, heat sealing, declaration etc. 72 Sr. No. Process Parameter 1. Packing Moisture, Fat , Salt, Acid value as Oleic Acid. Finished product analysis

High Protein Food: 

High Protein Food Raw material analysis 73 Sr. No. Raw material Parameters 1. Wheat flour Moisture%, Gluten%, Extraneous matter such as Rodent hair & Excreta 2. Soy flour - defatted Moisture%, Extraneous matter such as Rodent hair & Excreta 3. Rice flour Moisture%, , Extraneous matter such as Rodent hair & Excreta 4. Corn flour Moisture%, Extraneous matter such as Rodent hair & Excreta 5. Gram flour Moisture%, Extraneous matter such as Rodent hair & Excreta 6. Sugar Moisture, Foreign matter 7. Milk powder/whey powder Moisture,Physical Appearance, Taste & Flavor 8. Pure Salt/ common salt(Grade I) Foreign particles and physical condition

In Process Analysis: 

In Process Analysis Sr. No. Process Parameter 1. Drying Appearance, Shape , Crunchiness, Organoleptic quality Moisture 2. Spicing Flavor,Texture 74 Finished product analysis Sr. No. Process Parameter 1. Packing Calories, Moisture, Protein, Weight, Heat sealing integrity

Bakery : 

Bakery Raw material analysis 75 Sr. No. Raw material Analytical Parameter 1. Wheat flour Moisture content, gluten, ash content, acid insoluble ash, alcoholic acidity, sedimentation value, pH value, fermentation value, water absorption capacity. 2. Yeast Appearance, dough raising capacity, yeast live and dead cells, dispersability 3. Fat Melting point, iodine value, acid value

Finished Product Analysis: 

Finished Product Analysis Sr. No. Raw material Parameters 1. Bread Moisture content (% wb ) a. White Bread-40% b. Sweet Bread – 34% c. Fruity Bread – 28% Ash -0.1% Acid insoluble ash - Equivalent of 7.5 ml NaOH per 100 g dry bread pH – 5-6 76

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ENGINEERING SECTION 77

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Maintenance can be defined as the actions carried out in order to inspect, repair, service of a system or M/C. to ensure acceptable performance. Preventive maintenance and Breakdown maintenance of equipments are carried out in industries. Name of sub - units/sections: BOILER SECTION WATER SOFTENING PLANT REFRIGERATION SECTION EFFLUENT TREATMENT PLANT 78

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Boiler is used to provide the dry steam. There is a water softening plant, which produces soft water for boiler. Boiler Specification: Boiler Details Make Thermax , pune Capacity 2 TPH Fuel used F.O (Black oil ) Type Fire tube ( 3 pass smoke tube) Per day steam 24- 25 T Water requirement 30000- 32000 / day Operating Pressure 5.5- 9 kg/cm 2 Oil temp . When heated 120˚C Gas temp . & height of chimmney 150 ˚ C &100 ft 1 L oil 16 L of steam 79 BOILER SECTION

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Water is used in the food plays in various ways. 1. As an integral part of the product. 2. As a heating and cooling medium. 3. For cleaning of equipments and utensils. 4. Miscellaneous Specification of Water Softening Plant: Type - Ion exchange Resin - Zeo carb No. of tanks - 1 Capacity - 2000 LPH Initial water hardness - 300 ppm Treated water - Hardness 5-25 ppm TDS 150 max. pH 7-8 Consumption of soft water For boiler - 30000- 32000 lit/day. For plants - 15-20,000 lit/day. 80 WATER SOFTENING PLANT

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Necessary to restrict the growth of these microorganisms, which can be done by keeping them at low temp. Refrigeration is required at following places in food complex. Air coolers in chocolate plant. Cold stores. Ice bank tanks. Votator units in BSP . Commonly vapor refrigeration system is used in most of dairies due to better properties of refrigerant (Ammonia). Boiling temp . - -33.3ºC Critical temp. - 13.3ºC Freezing temp. - -77.7ºC 81 REFRIGERATION SECTION

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Plays very important role in controlling the pollution of water and soil by dairy effluent. They have aerobic type ETP . Waste water Discharge – Trade Effluent - 18000 liters /day Sewage Effluent - 4000 liters/ day Mode of Disposal – Gardening Hazardous waste Generation –ETP sludge 5Kg/ day 82 EFFLUENT TREATMENT PLANT

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83 Parameters Final outlet GPCB limits pH 8 6.5 – 8.5 Temp.˚C 30 40 SS (mg/l) 69 150 TDS(mg/l) 3040 2100 COD (mg/l) 76 Upto 250 BOD(mg/l) 19.5 Upto 100 Characteristics of effluents

PROJECT UNDERTAKEN VOLUNTARILY: 

Tried to incorporate wheat flour in malted food Objectives: To reduce the cost. Improve the quality & yield. Increase puffing. Reduce the loss of product. To reduce the fat content. 84 PROJECT UNDERTAKEN VOLUNTARILY

SUGGESTIONS : 

SUGGESTIONS To maintain hygiene in malted milk plant. To develop new variety of products in bread plant. Try to use sunflower or soy bean oil instead of palm oil in bread spread plant. To improve the quality of high protein products, should try different varieties of ingredients or their substitution. Try to improve the quality of chocolate . 85

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86 Thank You