OMFED Dairy Plant Report

INTRODUCTION The plant has been inaugurated with the support of the Fisheries and Animal Resources Development Department of Odisha. The newly inaugurated Dairy Plant is fully automatic as advance usage of technologies has been done due to which milk can be processed here in a relatively shorter per...

INTRODUCTION The plant has been inaugurated with the support of the Fisheries and Animal Resources Development Department of Odisha. The newly inaugurated Dairy Plant is fully automatic as advance usage of technologies has been done due to which milk can be processed here in a relatively shorter period of time. The National Dairy development board has approved technical consultancy in the design of this dairy plant September- 2021. VISION OF OMFED To be a leading milk producing organisation at international level of efficiency with widest and satisfied customer base, maximising wealth of stake holders & contributing to the state economy. MISSION Advancement of dairying, encouraging and educating people, through mutual participation. Continuous endeavour to increase productivity & per capita consumption. To promote clean milk production and distribution with state-of-art technology. Customer satisfaction with reliable, uninterrupted services and quality products. To foster a performance-oriented culture encouraging innovation. To promote a congenial work climate encouraging employees to participate and contribute for organisational growth. To be a learning organisation and responsive to changing environment. Continuous upgradation of skills & competence of employees & their career advancement. To enrich quality of life of people and preserve ecological balance. 1  MILK PROCUREMENT The backbone of OMFED is its Supply Chain that is efficiently managed by OMFED to suit to its customers' needs and meet the stated objectives. It follows a three-tier system which was originally pioneered by AMUL Dairy in Gujarat state of India. In Figure 1 the elemental composition/configuration of the three-tier operational system of OMFED is represented as: 1. The Village Co-operative Society (The actual Milk Producers) 2. The District Milk Unions/MU's (Collect milk from producers and provide them the required inputs) 3. The Milk Federation (Engaged in processing and marketing of milk) I. THE VILLAGE CO-OPERATIVE SOCIETY: It represents the first tier in the whole system. It is a voluntary association of milk producers in a District Milk Union. village who are willing to sell milk on a collective basis. Milk producers bring milk to the society every morning and evening. A sample of milk from each producer is taken and tested for quality. The society sells milk only to the nearest District Milk Union. II. THE DISTRICT MILK UNION(DMU): The Milk Union then carries the collected milk from the society by using hired transport vehicles to their processing centres. Milk is chilled to 5°C in the chilling centres. The collector of the district is the Chairman of the DMU. III. THE MILK FEDERATION: It provides for processing and marketing of milk and milk products. The chilled milk from MU is sent to the nearest federation dairy for processing, packing and marketing. The federation is managed by Board of Directors (BOD). The Federation has representation from various MUs and also from the State Government of Odisha. ➤Milk received at the plant from two milk union i.e., Cuttack Milk Union (CMU) & Puri Milk Union (PUMUL) Bulk Milk Cooler(BMC) from which milk come to plant Which is under CMU are -i) Nuapada, ii) Kendrapara, iii) Balikuda, iv) Banki, v) Mahanga, Bulk Milk Cooler from which milk come to the plant which is under the PUMUL is Nimapada. ► Surplus milk is the extra milk which is unable to processed by the plant due to capacity. Those milk has been sent to OMFED Arilo plant for processing. This milk has been received from -a) Sambalpur Dairy, b) Balasore Dairy, c) Bhawanipatna Dairy ► Surplus milks are -a) Raw chilled milk (RCM), b) Pasteurized skim milk (PSM), c) Pasteurized whole milk (PWM). 2 3  TANKER ENTRY AND WEIGHING BRIDGE At the time of tanker entry in the gate the challan slip checked and allowed the tanker for weighing. Weigh bridge used for measuring the tanker weight. In case of single chamber- At first the tanker containing milk has been weighed. Let it be W1 Then the tanker comes to Raw Milk Reception Dock. Then before unloading the sample of tanker checked. The quality control person shallcheck the seal, open it and plunger the milk with a tanker plunger from front to back at least for 25 times so as to make the milk homogeneous, check the temperature with the help of a digital thermometer and collect sample for testing and if approved by RMRD Lab then unloading done. After that empty tanker weighed. Let it be W2. Then quantity of milk = W1-W2 For double chamber front chamber (FC) & back chamber (BC): - Similarly, Weight of tanker containing milk = W1, Weight after unloading of one chamber (FC) = W3 Then weight of quantity of milk in front chamber (FC) = W1-W3 After that, Weight of empty tanker = W2 Weight of quantity of milk in back chamber (BC) = W3-W2 As gradually all these steps have been done. The RMRD Lab give a milk/cream reception voucher after receiving tanker. 4  RAW MILK RECEPTION LINE RECEIVING CRITERIA OF RAW MILK AT OMFED: Fat: Should not be less than 3.5% SNF: Should not be less than 8% Temperature: Should not be more than 10°C It should have clean and fresh flavour. Acidity: Should not be more than 0.15% L.A The milk should be neutralizer negative. It should be C.O.B negative. It should be adulterant negative. Methylene Blue Reduction Test (MBRT) should be minimum 30min. PROCESS FLOW DIAGRAM: Raw chilled milk comes from Surplus milk received in the milk union in tanker tanker Weighing Sampling Rejected tanker Lab analysis sending back Accepted tanker (temperature of milk4-5°C) Unloading of tanker (Tanker ID selected) Hose pipe is connected from tanker valve to 5  the deaerator through the pneumatic valve Deaerator capacity 200L When raw milk fills to the upper sensor of deaerator then only it starts to flow. Duplex inline strainer Number of strainer -2 Capacity of each strainer 30KLPH Both run at a time Uploading pump (Capacity 30 KLPH) PID valve Chilled water supply Temperature 4-5°C Raw milk chiller Chilled water return Capacity 30KLPH Temperature 3° Raw milk storage tank (RMST) Number of RMST-2 Capacity of each tank 100KL 6  LIQUID MILK PROCESSING SECTION FLAVOURED MILK: DEFINITION: Flavoured milks are milks to which some flavours have been added. When the milk is used, the product should contain a milk fat percentage at least equal to the minimum legal requirement for market milk. But when the fat level is lower (1-2 per cent) the term 'drink' is used. Two types of Normal Sweet Flavour Milk manufacture at OMFED plant: 1.Kesar flavour milk 2.Elaichi flavour milk FLOW CHART FOR NORMAL SWEET FLAVOURED MILK: Receiving Pasteurized (Premium cow milk, FAT: 3.5% & SNF: 8.5%) Standardization (Adding sugar@8% of batch volume) (Rest of the SNF % from Skim milk powder @5.35% to 5.5%). (Standard: Fat: 1.5% ,Sugar: 8%) Taking flavoured milk tank(quantity -2,capacity of each-1000L) (Agitation for 15-20min and then sampling) Addition of flavour For Kesar flavour milk: - Kesar milk masala(Kg)@0.1% Saffron flavour (LTR)@0.2% of batch volume FO9 Tartrazine colour (Kg)@ 0.005% of batch volume For Elaichi flavour milk: - Cardamom flavour (LTR)@ 0.059% of batch volume No colour addition (Agitation for 15 min & then sample testing) 7  Bottling/Filling (Turn table-→Bottle air jet cleaning machine >Filling machine(6bottle at a time) (Leak testing machine-Conduction Sealing machine(6bottles sealed at a time) Sterilization (121°C and holding for 15min) Cooling at 53oC Capping/ Printing/ Labelling (Turn table→ inner capping machine → printing machine → steam heating tunnel(85-90°C) Cartooning (Web sealing machine having 2 heaters /temperature: 121°C and 220°C) Shrink wrapping Storage Reception of A2 milk: - 1. A hose pipe is connected from the tanker valve to the pump of reception section for unloading of tanker. The capacity of the pump is 12000 LPH. 2. Then the A2 milk transfer to the balance tank. 3. From there it moves to the pasteurizer for pasteurization and heated to 82°C by the hot water from hot water vessel. Pasteurizer is of 3KLPH capacity. 4. Then the A2 milk is homogenized at 65°C in the homogenizer of 1000 LPH. 5. lt passes to the holding tube and holds for 15 seconds. Then chilled in the pasteurizer to 3°C by chilled water. 6. Then collect in the tank and manually filled in the can. 7. Then keep in the cold store at 6-7°C. 8 FLOW CHART FOR A2 DESI COW MILK(IMMUNO-BOOSTER MILK) Receiving Pasteurized/Homogenized A2 milk (Fat: 4.1%, SNF: 8.6%) Standardization (Adding water to decrease SNF 8.6%) Agitation for 15-20min & then sampling/testing Final batch Bottling/Filling (Turn table->Bottle air jet cleaning machine-→Filling machine (Leak testing machine-Conduction Sealing machine Sterilization (121°C and holding for 15min) Cooling at 53°C Capping/ Printing/ Labeling (Turn table->inner capping machine->printing machine-→steam heating tunnel (85-90°C) Cartooning (Web sealing machine having 2 heaters /temperature: 121°C and 220°C) Shrink wrapping Storage 9  FLOW CHART FOR MANUFACTURING OF A2 SFM: Receiving Pasteurized/Homogenized A2 milk in can (Fat: 4.1%, SNF: 8.6%) Standardization (Adding water to decrease SNF 8.6% to 8.3%) Adding sugar@8% of batch volume Final batch testing fat: 3.2% (min), SNF: 16.30% (min) Taking flavoured milk tank (quantity -2, capacity of each - 1000L) (Agitation for 15-20min and then sampling) Addition of flavour For Kesar flavour: - Kesar milk masala (Kg)@0.1% Saffron flavour (LTR)@0.2% of batch volume F09 Tartrazine colour (Kg)@ 0.005% of batch volume For Elaichi flavour: -Cardamom flavour(LTR)@0.05% of batch volume No colour addition (Agitation for 15 min & then sample testing) Bottling/Filling (Turn table Bottle air jet cleaning machine-Filling machine(6bottle at a time) →Conduction Sealing machine(6bottles sealed at a time) Leak testing machine Sterilization (121°C and holding for 1Smin) Cooling át 53°C Capping/ Printing/ Labeling 10  (Turn table→inner capping machine-→printing machine->steam heating tunnel(85- 90) Cartooning (Web sealing machine having 2 heaters /temperature: 121°C and 220°C) Shrink wrapping Storage TRADITIONAL PRODUCTS: KHOA: Khoa is a concentrated whole milk product obtained by open pan condensing of milk under atmospheric pressure. Definition: According to Food Safety and Standard Regulations 2011, Khoa, by whatever variety of names it is sold such as Pindi, Danedar, Dhap, Mawa or Kava, means the product obtained from cow or buffalo or goat or sheep milk or milk solids or a combination thereof by rapid drying. The milk fat content shall not be less than 30 percent on dry weight basis of finished product. It may contain citric acid not more than 0.1 percent by weight. It shall be free from added starch, added sugar and added colouring matter. PROCESS FLOW CHART OF KHOA Raw chilled millk Transfer to Khoa vat Heat to boil Boil with stirring till the volume become about 1/ of the milk Transfer to container and cool to room temperature Sealing by mechanical heater Cartooning and Storage Despatch 11 PEDA: Peda is a sweet prepared from pindi variety of khoa by the addition of sugar. Since peda contains sugar and lower moisture content it has a better keeping quality than khoa. Peda has religious importance as they are offered as "Prasad" during worship of God in the temples. Peda is also offered to guests at the time of ceremonial celebration like marriages etc. Some region-specific varieties are popular in different regions of the country. Doodh peda is the common variety and is popular all over India. Peda is characterized as a circular slightly flattened ball with low moisture content and white to creamy white in colour and smooth texture. PROCESS FLOW CHART OF PEDA: Raw chilled milk Transfer to Peda vat Heat it to boil Boil with stirring till the volume become about 1/5 of the milk Add sugar 35% of produced Khoa and continue heating for 15 min. Allow for cooling up to room temperature Prepare Peda as per required size Sampling &testing Packaging Cartooning &storage Despatch 12 RABIDI: Rabidi is a sweetened concentrated whole milk product with thickened malai laver obtained by evaporation and concentration of milk. Buffalo milk is preferred for preparation of rabidi. PROCESS FLOW CHART OF RABIDI: Raw chilled milk Transfer to Rabidi vat Heat it to boil Addition of sugar @ 4.5 % of milk Boil with stirring till the volume become about 1/3 of the milk Filling in cups and transferred to cold store Sealing of cups by mechanical heater Sampling & testing Cartooning and Storage Despatch 13 PANEER: Paneer is a heat-acid coagulated milk product obtained by coagulating standardized milk with the permitted acids at specified temperature. The resultant coagulum is filtered and pressed to get the sliceable curd mass. Paneer has a firm, close, cohesive and spongy body and smooth texture. FSSR - 2011 STANDARDS OF PANEER: Paneer means the product obtained from the cow or buffalo milk or a combination thereof by precipitation with sour milk, lactic acid, or citric acid. It shall not contain more than 70% moisture and milk fat content shall not be less than 50% of the dry matter. Milk solids may also be used in the preparation of paneer. Low fat paneer shall contain no more than 70% moisture and not more than 15% milk fat on dry matter basis. PROCESS FLOW CHART OF PANEER: Raw milk Heating at 90°C for 10 mins. Cooling at 80 to 85°C Coagulant GDL(Gluconic Delta Lactone) @O.35% of milk is dissolved in water at 85°C Solution is added uniformly with the milk by continuous stirring to coagulate properly for 15-20mins. Kept as such for 1o minutes after Agitation The chena is put in the hoops The whey is drained 14  The hoops are pressed under 2bar pressure for 1Ominutes The paneer blocks are dipped in the pasteurized chilled water vat(capacity: 2KL) for 3-4 hour (Temperature of chilled water 3-4°C) The paneer blocks are transferred to cold store. (Temperature 3-8°C) Cutting and vacuum packing Sampling &testing Storage in cold store below 5°C Despatch FERMENTED PRODUCTS SECTION Fermentation is one of the simplest ways of preserving milk constituents for human consumption. Fermentation gives an acid taste to milk which is particularly refreshing in worm climate and also imparts certain therapeutic benefits originally absent in milk. Some of the popular Indian fermented milk products which produced in OMFED plant are:- Dahi(Plain curd & Whole milk curd), Sweet Curd DAHI OR CURD: Definition of Dahi Dahi or curd is a semi solid product, obtained from pasteurized or boiled milk by souring, using harmless lactic acid or other bacterial cultures. Dahi may contain additional cane sugar. It should have the same minimum percentage of fat and solids- not-fat as the milk from which it is prepared. Where dahi or curd other than skimmed milk dahi, is sold or offered for sale without any indication of the class of milk the standards prescribed for dahi prepared from buffalo milk shall apply. 15 PLAIN CURD (PC): PROCESS FLOW CHART FOR PREPARATION OF PLAIN CURD: Pasteurized milk storage tank (Standard :Fat-3.7%,SNF-14.2%) Curd milk silo (quantity ;2,capacityof each :20KL) (In CMS fat :3.70%,SNF:14.18%) Pasteurization (90 for 10 min) Chilling at 3°C Curd milk silo (Omfed standard for plain curd: Fat- 3.5%, SNF - 14%) Curd milk heater (capacity - 5KL, temperature:40-50°C) Inoculation tank(IIT-1 & IT-2 : 2000L) (IT-3,IT-4 & IT-5: 500L) Culture addition (Thermophilic culture, Freeze dried lactic culture for Direct Vat Set: STI 13) (1000ml culture used for 2000L Milk) (1000ml Culture prepare by using 1000ml distilled water+1 packet STI 13 freeze dried lactic culture) Agitation for 15-20min Curd milk transfer to cup filling machine or pouch filling machine Incubation room(temperature: 40-43°C, 4Hours) Acidity checking by lab to check whether the curd settle & then transfer to 16  the pre cooling room Transfer to cold storage or cold blast room( temperature: 3-4°C) keep it for overnight Packing in secondary package WHOLE MILK CURD(WMC): PROCESS FLOW CHART FOR MANUFACTURING OF WMC: Pasteurized Milk storage tank (Standard: Fat-3.7%, SNF- 14.2%) Curd milk silo (quantity:2, capacity of each: 20KL) (In CMS Fat: 3.70%, SNF: 14.18%) Pasteurization (90°C for 10min.) Chilling at 3°C Curd milk silo (Omfed standard for whole milk curd: Fat: 3.0%, SNF: 11.5%) [In CMS Pasteurized water(Water pasteurized at 90°C for 20S) added to adjust the fat and SNF percentage ] Testing of FAT & SNF by laboratory Curd milk heater (capacity - 5KL, temperature:40-50°C) Inoculation tank(IIT-1 & IT-2: 2000L) (IT-3,IT-4 & IT-5: 500L) Culture addition (Thermophilic culture, Freeze dried lactic culture for Direct Vat Set: STI 13) (1000ml culture used for 2000L Milk) (1000ml Culture prepare by using 1000ml distilled water+1 packet STI 13 freeze dried lactic culture) 17  Agitation for 15-20min Curd milk transfer to cup filling machine or pouch filling machine Incubation room(temperature: 40-43°C, 4Hours) Acidity checking in lab to check whether the curd settle and then transfer to the pre cooling room Transfer to cold storage or cold blast room( temperature: 3-4°C) keep it for overnight Packing in secondary package SWEET CURD OR MISTI DAHI: It is a traditional sweetened fermented milk product popular in the eastern part of India, notably West Bengal, Bihar and Assam. It is prepared by lactic acid fermentation of sweetened milk. Misti dahi is regarded as a special dessert on ceremonial occasions both in the rural and urban Bengal. The product is commonly available in earthen pots of different sizes. A good misti dahi has a characteristic brown colour,firm consistency, smooth texture and caramelized flavour. PROCESS FLOW CHART FOR PREPARATION OF SWEET CURD: Raw milk storage tank (100KL) Multi-Purpose Vat(capacity -2000L)( Heating to 45°C by heater) (Multipurpose Vat → pump→ Duplex filter(10KLPH)→Heater (5KLPH)→MPV) Milk transfer to Duplex filter through mixing pump(2KLPH) 18 Turboblender(18.5% sugar and Skim milk powder added for Standardization) (Heating to 90°C by using Sweet Curd Reconstitute heater) Multipurpose Vat Chilling to 32°C(if happened then milk transfer to sweet curd milk heater (1KLPH) through pump (2KLPH) for achieving the inoculation temperature about 44°C) Inoculation tank [ culture addition (Freeze dried lactic culture : ST 805 & ST 807)(1000ml culture used for 2000L Milk) (1000ml Culture prepare by using 1000ml distilled water+1 packet ST 805 or ST 807 freeze dried lactic culture) Agitation for 15-20min Curd milk transfer to cup filling machine or pouch filling machine Incubation room(temperature: 43°C, 8-10Hours) Acidity checking in lab to check whether the curd settle and then transfer to the pre cooling room Transfer to cold storage or cold blast room( temperature: 3-4°C) Keep it for overnight Packing in secondary package Despatch 19  CIP SECTION FOR PRODUCTION BLOCK WHAT IS CIP? Cleaning-in-place or CIP refers to cleaning of all sanitary pipelines by circulation. It may be defined as circulation of cleaning liquids through machines and other equipment’s in cleaning circuits without dismantling the equipment. The high velocity flow of liquid over equipment surface generates mechanical scrubbing effect that dislodges deposits from vessels and pipelines. The majority of cleaning and sterilizing liquids used in CIP systems are alkali or acid based. Automated CIP systems allow accurate dosing of the concentrated cleaning agent, normally into water, to give a low strength solution suitable for cleaning process plant. This solution is used within the plant to clean and sometimes, sterilize the system prior to the next production run. CIP can be carried out with automated system. CIP OF TANKER, PROCESS SECTION AND FERMENTED SECTION: PROCESS FLOW CHART: CONCENTRATED CIP CHEMICAL STORAGE SECTION: Three processes are involved in CIP:- I. Sterilization: For emergency purpose and for line II. LYE+ Sterilization: For all and every day III. Complete: For all Pasteurizer after 2-3 days other 5-6 days Lye CIP Short CIP CIP FOR FERMENTED SECTION CIP has been done by five processes: I. Sterilization: Steps involved:- A. Pre rinse with fresh water, for 30seconds utilized from fresh water tank of 5KL capacity. After primary cleaning this water is drained. B. Sterilization is done by hot water for 300seconds utilized from hot water tank of 5KL capacity. Again, this return to the same tank. Hot water forward temperature:80°C Hot water return temperature: 60°C c. Final rinsing with fresh water for 30seconds and this fresh water again go back to fresh water tank of 5KL capacity. 20  Final rinse forward tem6: 35°C Final rinse return temperature: 60°C Steps involved A. Pre rinse with fresh water for 30seconds, utilized from fresh water tank of 5KL capacity. And then this water is drained out. B. Lye rinsing has been done for 300seconds, used from Lye tank of 5KL capacity. And after cleaning again back to the same tank. Lye forward temperature: 80°C Lye return temperature: 55°C Intermediate rinse forward temperature: 50°C C. Inter rinsing with recuperation water for 30seconds, used from the recuperation tank of 5KL capacity. Again, this water come back to the same tank. Recuperation water is the return water not reaching the desired temperature, collection the recuperation tank. D. Rinsing with acid for 300seconds, used from the Acid tank of 5KL capacity. Again, this acid return to the same tank. Acid forward temperature: 75°C Acid return temperature: 50°C E. Again, intermediate rinsing is done for 30seconds. F. Again, rinse with Lye for 120seconds. G. Intermediate rinsing done for 30seconds. H. Again, sterilized with hot water for 30seconds. I. Final rinsing with fresh water for 30seconds, utilized from fresh J. water tank of 5KL capacity. These waters then return to the same tank. Final rinse forward temperature: 35°C Final rinse return temperature: 60°C K. Remaining water in tank drained for 20seconds. II. (a) Lye + Sterilization for tanks: Steps involved:- A. Pre rinse with fresh water for 60secconds. B. Intermediate stop for 10seconds line is being empty. C. Lye rinsing for 300seconds. D. Intermediate push with fresh water for 25 seconds. E. Again, Intermediate stop for 10seconds. Line is being empty. F. Intermediate rinse with recuperation water for 30second. G. Intermediate stop for 10secondsvline is being empty. H. Sterilized with hot water for 3000seconds. I. I. Again, intermediate stop for 10seconds. Line is being empty. 21  J. Final rinse with fresh water for 30seconds. K. Draining of remaining water in tank for 10seconds. (b) Lye + Sterilization for machines & filling machine lines: Steps involved:- A. Pre rinse with fresh water for 60seconds B. Lye rinse has been done for 1200seconds. C. Intermediate rinsing with recuperation water for 30seconds. D. Sterilization by hot water for 300seconds. E. Final rinsing with fresh water for 30seconds. 4. Lye CIP: Steps involved:- A. Pre rinse with fresh water for 120seconds. B. Lye rinsing has been done for 600seconds. C. Final rinse with fresh water for 60seconds. 5. Short CIP: Steps involved:- A. Pre rinse with fresh water for 120 seconds. B. Rinse with Lye for 600seconds. C. Intermediate rinse with recuperation water mixed with both acid A. and lye for 120seconds. D. Acid rinse has been done for 500 seconds. E. Again, intermediate rinsing is done. F. Again, rinse with Lye for 200 seconds. G. Final rinse with fresh water for 60 seconds. For raising all the forward temperature two make-up line is there having two PHE of 20KLPH capacity for reaching the desire temperature. Mostly Lye Sterilization is done for all the machines, lines and tanks. But after 2-3 days complete process of CIP is done for the machine and it's transfer line and holding coil. And for tanks and other modules, transfer lines complete process of CIP has been done after 6-7 days. Short and Lye process of CIP used at the time of emergency and less time. 22  ACTIVITIES OF QUALITY CONTROL LABORATORY SUGAR TEST FAT TEST SALT TEST AMMONIA TEST UREA TEST GLUCOSE TEST ACIDITY TEST HYDROGEN PHEROXIDE TEST NEUTRALIZER TEST PROTEIN TEST Adulteration: Adulterant means any material which is or could be employed for making the food unsafe or sub-standard or misbranded or containing extraneous matter. Adulterated food is dangerous because it may be toxic and can affect health and it could deprive nutrients essential for proper growth and development. Adulteration of milk reduces the quality of milk and can even make it hazardous. Adulterations like salt, sugar, Ammonia, vegetable oil which increase the fat, SNF etc. of milk. ADULTERATION CHECKED BY USING NDDB KIT:- Procedure for using the kit:- UREA DETECTION 1. Take 2ml. milk. 2. Add 2ml. Urea Reagent and mix well Distinct yellow colour: Urea has been added to milk. AMMONIA FERTILIZERS DETECTION 1. Take 1ml. milk. 2. Take 2ml. Ammonia Reagent and mix well. Brownish colour: Ammonia fertilizer have been added to milk. NITRATE FERTILIZERS/POND WATER DETECTION 1. Rinse test tube with 5ml. milk. 2. Add 1ml. of Nitrate Reagent along the sides of the tube. Blue colour: Nitrate Fertilizers/Pond Water have been added to milk. STARCH AND CEREAL FLOURS DETECTION: 1. Boil 5ml. of well-mixed milk and cool it. 2. Add few drops of Starch Reagent. Blue colour: Starch and Cereal Flours have been added to milk. 23 SUGAR/SUCROSE DETECTION: 1. Take 1ml. milk. 2. Add 1ml. Sugar Reagent. 3. Place in boiling water for 3-5 minutes. Red colour: Sugar has been added to milk. GLUCOSE DETECTION : 1. 1.Take 1ml. milk 2. Add 1ml. Glucose Reagent -I 3. Place in boiling water for 3 minutes and cool. 4. Add 1ml. Glucose Reagent -Il Deep Blue colour : Glucose has been added to milk. SALT DETECTION: 1. Take 5ml Salt Reagent -I 2. Add few drops of Salt Reagent -ll(red colour develops) 3. Add 1ml. milk and mix well. Yellow colour: Salt has been added to milk. NEUTRALIZER DETECTION: 1. Take 2 ml Milk. 2. Add 2 ml reagent and mix well. Rose red / pink colour : Neutralizer has been added to milk. HYDROGEN PEROXIDE DETECTION: 1. Take 1ml. milk. 2. Add few drops of Hydrogen Peroxide Reagent and mix well. Pink/Red colour: Hydrogen Peroxide has been added to milk a. Take 1ml 0.1 (N) silver nitrate in test tube b. Add 2 to 3 drops potassium chromate ADULTERATION TEST FOR RAW MILK CHECKED BY MANUALLY: Sugar Test: a. Take 1ml Milk b. Take 1ml sugar solution (0.5% resorcinol 35%HCL) c. Shake the test tube properly. d. Boil for 4 to 5 minutes, If red colour appeared, test is positive. 24 Salt Test: a. Take 1 ml 0.1 (N) silver nitrate in test-tube. b. Add 2-3 drops potassium chromate. c. Add 3 ml milk d. Shake the test tube properly e. If the yellow colour appears the test is positive Urea Test: a. Take 2 ml urea solution (Para diethyl amino Benzaldehyde) b. Take equal amount of milk c. Shake the test tube properly d. If yellow colour appears test is positive. Starch Test: a. Take 3 ml milk b. Boil the milk c. Then cool it d. Add 2 to 3 drops iodine sol (1%) c. Shake it properly if blue colour appears the test is positive. Acidity Test: a. Take 10 ml milk in a beaker. b. Then add 10 ml distilled water. c. Add 8-10 drops of phenolphthalein. d. Then titrate with N/10 NaOH solution up to light pink colour. e. Note the reading. f. Acidity = 9AN/W (where, A = Burette reading, N = Normality of NaOH, & d. W = Volume of sample) Neutralizer Test: a. 2 ml milk sample. b. 2 ml alcoholic solution (60% Ethyl Alcohol+1% Rosalic acid) c. Shake it properly if pink colour appears the test is positive. Ammonia Test: a. Pipette 5 ml of suspected Milk sample into a test tube. b. Add 1 ml of Nessler's Reagent. c. Mix the contents of the tube thoroughly. d. Observe and note the colour. If yellow in brown appeared test is positive 25 Detection of Glucose: a. Take 1 ml milk in a test tube. b. Add 1ml of Barford's reagent & Mix c. Heat the Mixture for extract 3 min in a boiling water bath. d. Cool rapidly & add 1 ml of Phosphomolybdic reagent e. If Deep Blue colour indicates Glucose f. Tests for Presence of Sulphates in Milk Reagents: Barium chloride (BaCl2.2H20) 5% (w/v) aqueous solution: Dissolve 5.0 g barium chloride in distilled water and make the final volume to 100 ml. Acetic acid 4% (V/V, aq.): Dissolve the 4 ml of Acetic acid into distilled water and make the final volume to 100 ml. Procedure: a. Take 10 ml of milk in a 30 ml test tube. b. Add 2 ml of Acetic acid solution shake, boil & cool. c. Filter the coagulated milk through Whatman filter paper Grade 42. d. Take 5 ml of clear filtrate. Add few drops of barium chloride solution. Observation: Observe for any visible precipitates in the tube. Formation of milky-white precipitates indicates the presence of Sulphate, like ammonium sulphate, sodium sulphate, zinc sulphate and magnesium sulphate etc. to milk. The limit of detection of method is 0.05%. Test for Presence of Hydrogen Peroxide in Milk: Reagents: Potassium iodide solution: Weigh 20g of potassium iodide and dissolve it in distilled water to obtain a 100 ml solution. Starch solution: Take 1g starch powder and dissolve it in distilled water by heating and make up the volume to 100 ml. Potassium iodide-starch reagent: Mix equal volumes of 20% potassium iodide solution and 1% starch solution Procedure: a) Take 1 ml of milk sample in a test tube. b) Add 1 ml of the potassium iodide starch reagent and mix well. 26 Observation: Observe the colour of the solution in the tube. Blue colour will be developed in the presence of H202, whereas pure milk sample remain white in colour. Test for Presence of Formalin in Milk: Reagent: Concentrated sulphuric acid. Procedure: Take milk sample (5ml) in a test tube and add 5 ml of 90 percent H2S04 containing traces of ferric chloride from the side of the test tube slowly. Observation: Formation of purple ring at the junction indicates formaldehyde is present in milk. QUALITY OF RAW MILK AUTOMATICALLY CHECKED BY MILKOSCAN: The Milko Scan TM FT1 analyser is dedicated to liquid dairy production. It allows you to control and standardise liquid dairy products while simultaneously screening for abnormalities. It is ideal for: Rapid control at the platform for optimal segregation and screening for abnormalities Milk standardization for optimal use of raw material and consistent quality products Monitoring the quality of final products PARAMETERS NATURAL ADULTERATED FAT % AMMONIUM SULPHATE SNF % DETERGENT PROTEIN % MALTOSE TOTAL SOLIDS % MELAMINE LACTIC ACID % SALT LACTOSE % GLUCOSE LOW LACTOSE % SODIUM CARBONATE GALACTOSE % STARCH FREEZING POINT % SUCROSE DENSITY % UREA CITRIC ACID % FORMALDEHYDE FREE FATTY ACID % HYDROXY PROLINE UREA VEGETABLE OIL CASEIN 27 Electroscope FT-A (automatically measure different parameters of raw milk as well as products) :- Parameters: Fat, SNF, solids, protein, Lactose, acidity, casein, FFA,(formaldehyde, H202, citrate, detergent, fructose, glucose, galactose, maltose, melamine, sorbitol, sucrose, nitrate, urea, Sulphate, vegetable oil ammonium, Maltodextrin, starch, salt) Filling: a. Fill the container with DECON 90(Cleaning liquid). b. Fill the container with TRITON X-100(zero liquid). Procedure: a. Turn on the computer and monitor. b. Start the results plus software. c. Air bleeds the liquid system with the de-air procedure. d. Perform an auto clean with zero. e. Raw milk 50 ml take in a beaker and heated to 40°C and mix well. f. For the product dilute it to 50% with distilled water and heated to 40o C and mix well in magnetic stirrer. g. Then put the sample in the machine and dip the pipette in to it. h. Rename the product and analyse the results. ANALYSIS OF RAW MILK 1. FAT TEST: Procedure: a. Heat the sample at 40°C in water bath and subsequently cool to 27°C b. sample of Gerber sulphuric acid from the tilt measure in the milk Butyrometer. c. Pipette out 10.75 ml of well mixed milk sample at 27° C and transfer 1mlof isoamyl alcohol (specific gravity 0.803-0.815) using a tilt measure. d. Use stopper and mix the contents well by shaking. e. Centrifuge it for 5 minutes at 1200 rpm. f. After centrifuging take the reading. 28 2.DETERMINATION OF SNF USING LACTOMETER: Procedure: a. The milk sample at 40°C in water bath and subsequently cool to 27°C. b. Rinse the lactometer cylinder with sample and pour sample into lactometer Cylinder. c. Place lactometer in milk and allow it to come to a constant level d. Read the lactometer reading as soon as possible at 27° C e. Formula of SNF = {(CLR + FAT)/4}+0.44. TEST FOR BUTTER: DETERMINATION OF FAT CONTENT IN BUTTER: Principle: The Gerber acid dissolves the protein and other milk solids and creates heat which liquefies and de- emulsifies the fat. Iso - amyl alcohol is added to aid the separation of fat. Apparatus: Butter butyro (0-100 percent), centrifuge machine, weighing balance Reagents: Gerber sulphuric acid 90 percent. Prepared by mixing 90ml volume of concentrated sulphuric acid and 1ml volume of distilled water in a measuring cylinder. After mixing properly keep it undisturbed for 5 minutes. Then use it.Iso- Amyl alcohol : Specific gravity 0.803 to.805 at 27 ° C. Procedure: a. Take 10ml sulfuric acid in the 100% reading butyrometer. b. Then measure 5g of butter sample on that butyrometer containing acid by taking the Butyrometer before measuring 5g of butter in the weighing balance machine with the help of glass rod put the butter sample in the butyrometer. c. After that add warm water for melting the butter and mixing properly. d. Add 1ml Iso-amyl alcohol. e. Close the mouth of butyrometer by the rubber stopper. f. Mix it properly by inverting the butyrometer. g. Then centrifuge the butyrometer in Gerber centrifuge at 1200rpm for 5 minutes. Then note the reading in butyrometer. 29 DETERMINATION OF CURD IN BUTTER: Principle: Fat portion is removed with the help of petroleum ether and residue left behind is dried for determination of curd content. In case of table butter, it is curd and salt content and thus salt content has to be determined separately for calculating curd content. Procedure: a. Take 5g of white butter in a aluminium dish. b. Put the dish with sample in the hot air oven at 102°C fir 3 hours. c. Take out the sample and boil it over a burner by holding the aluminium d. Continue boiling until a brown precipitate observed. e. Now wash the sample with petroleum ether (boiling point: 60-80°C) f. Then put the aluminium dish containing the brown residues in the hot air oven at 102°C for 30minutes. g. Now take the weight of a aluminium foil. h. And weight the dried Curd particles in the aluminium foil. Calculation: Weight of aluminium foil = W, Weight of aluminium foil with curd particles = W1, So, weight of curd particles = (W-W1)g ANALYSIS OF GHEE: DETERMINATION OF FAT CONTENT IN GHEE: Principle: The Gerber acid dissolves the protein and other milk solids and creates heat emulsifies the fat. Iso- amyl alcohol is added to aid which liquefies and the separation of fat. Apparatus: Butter butyrometer (0-100 percent ), centrifuge machine, weighing balance Reagents: Gerber sulphuric acid 90 percent Prepared by mixing 90ml volume of concentrated sulphuric acid and 1ml volume of distilled water in a measuring cylinder. After mixing properly keep it undisturbed for 5 minutes. Then use it. Iso- Amyl alcohol: Specific gravity 0.803 to.805 at 27°C. Procedure: 30 Take 10ml sulfuric acid in the 100% reading butyrometer Then measure 5g of ghee sample on that butyrometer containing acid by taking the Butyrometer before measuring 5g of ghee in the weighing balance machine and put the ghee sample in butyrometer. After that add warm water for melting the ghee and mixing properly. Add 1ml Iso-amyl alcohol. Close the mouth of butyrometer by the rubber stopper. Mix it properly by inverting the butyrometer. Then centrifuge the butyrometer in Gerber centrifuge at 1200rpm for 5 Minutes. Then note the reading in butyrometer. MICROBIAL TESTS FOR RAW MILKAND MILK PRODUCTS Methylene Blue Reduction Test(MBRT): Principle: The methylene blue reduction test is based on the fact that the colour imparted to milk by the addition of a dye like Methylene blue will disappear more or less quickly. The removal of the oxygen from milk and the formation of reducing substances during bacterial metabolism cause the colour to disappear. The agents responsible for the oxygen consumption are the bacteria. Though, certain species of bacteria have considerably more influence than others, it is generally assumed that the greater the number of bacteria in milk, the quicker will the Oxygen be consumed, and in turn the colour will disappear. Thus, the time of reduction is taken as a measure of the number of microorganisms in milk. Although, it is likely that it is more truly a measure of the total metabolic reactions proceeding at the cell surface of the bacteria. The test is useful in assessing the bacteriological quality of milk by determination of the time taken for the reduction of methylene Blue in milk indicated by its colour change. Preparation of Methylene Blue solution : Add 0.5g of 1tablet of Methylene Blue to 800ml distilled water and hold the solution for 24 hours in the refrigerator. Then use it. Procedure: a. Take 10 ml of milk in a test tube. b. To this take 1ml of Methylene blue bench solution with a sterilized Pipette. c. Replace the cotton plug with a rubber bung which has been sterilized. d. Mix it by inverting up and down and keep it in water bath maintained at 37°C. e. Invert it once every half-an-hour and check for disappearance of blue colour. f. Record the time at which the colour disappears. Grade for Methylene Blue reduction test : MBRT ( hrs ) Grade >/ = 5 Very good 3-4 good 1-2 Fair ,