Practical Manual—

Dairy Products-II EXPERIMENT 17 VISIT TO DAIRY

PRODUCT
MANUFACTURING
PLANT
Structure

17.1 Introduction
17.2 Objective
17.3 Experiment
Procedure

17.1 INTRODUCTION
Dairy plants engaged in the manufacture of several products are known as dairy
products factory. The product mix is decided by the entrepreneur depending upon
several factors like available facilities in the factory, availability of the raw materials,
technical know-how, competence of the workers, market demands, profitability
etc. before starting the production. In this exercise the students will observe
manufacturing processes for various products and the facilities required for them
in a dairy plant. They will also learn the marketing requirements for various
products.

17.2 OBJECTIVE
l To get familiar with the various activities of a dairy product manufacturing plant

17.3 EXPERIMENT
1. Procedure
l Visit a dairy product factory.

l Observe and record the following observations

l Name of dairy plant

l Location

l Total area

l Type of organization: Govt / Public sector / Co-operative / Private sector

l Date of commissioning

l Capacity of the plant

l Equipments available in the plant

Name

56 Type
 Make Visit of Dairy Product
Manufacturing Plant
Capacity

l Various sections in the plant

l Number of personals working in the plant

Administrative

Technical

Supporting

l Product handling method: Manual/ semi automatic/ automatic

l Quantity of milk procured—————————

l Source of milk supply: Farm/Co-operative/ Private agencies/ Chilling centers/

others

l Equipments available at reception dock:

l Tests carried out to assess the quality of milk at reception dock: Sensory,
chemical and microbial tests.

l Method of storage of raw milk: Number of storage tanks/Silo/Overhand

tank

Capacity:

Processing of milk

Method of pasteurization: Batch/Continuous

Capacity of pasteurization plant:——————————l/hr

Functioning of Flow diversion Valve:————————————

Packaging machines: Make——————— Capacity————————

Other equipments: Homogenizer, blender, vats, balance tank etc.

Name of the products manufactured in the plant

Cream products: Sterilized cream/ Whipped cream/ Plastic cream etc.

Quantity of milk separated ——— Yield of cream ————, %yield——

Fat % in milk—— Fat % in cream—— % recovery of fat in cream ———

Butter / butter spread

Quantity of cream used ——— Yield ————, %yield ——

Fat % in cream —— Fat % in butter —— % recovery of fat in butter ——

57
Practical Manual— Ghee
Dairy Products-II
Quantity of cream/butter used ———— Yield————, %yield——

Fat % in cream/ butter—— % recovery of fat in ghee————-

Cheese

Type of cheese manufactured————————————-

Quantity of milk used————— Fat: Casein ratio in milk———————

% Yield of cheese—————

Ripening room temperature ——————°C

Processed cheese/cheese spread

Type of cheese used _____________

Proportion of different cheese used for processing——————————

Name of the emulsifier _____________

Quantity_____________ Rate __________%

Colour _____________ Quantity __________ Rate__________%

Name of preservative_______ Quantity __________ Rate _________%

Condensed milk/ Evaporated milk

Quantity of milk used:

Quantity of condensed milk/evaporated milk made:

Type of evaporator used:

Method of packaging :

Capacity of the evaporator:

Ice cream

Type:

Ingredients used:

Quantity manufactured:

Method of packaging: Bulk/ Retail

Hardening room temperature: ——————°C

Milk powder—SMP/WMP/Infant food/ Coffee whitener/ weaning food

Quantity of milk used:

58
Quantity of milk powder: Visit of Dairy Product
Manufacturing Plant
Type of drier:

Capacity of the drier:

Method of packaging:

Other products manufacture: Fermented milk products, Indian dairy products,

infant foods, etc.

l Cleaning procedures: Manual/CIP

l Quality control:

l Facilities available
l Sensory, chemical and Microbial tests followed to asses the quality of
milk and milk products
l Tests conducted on quality of water, detergents and equipments etc.
l Utilities
Observe the following
l Operation of CIP, strength of detergents used, Pumps
l Refrigeration – flow diagram of refrigeration, Number of compressors,
refrigerant used, Ice Bank Tank capacity etc.
l Boiler – Type of boiler, Capacity, Number of boilers, Make, Water
softening unit
l Generator – Type, Make, Capacity, Number of generator
l Effluent treatment plant – type, capacity, operation, tests followed,
use of treated water
l Consumables- Source of water, electricity, coal etc.

Note: Study guide for the above experiments is Laboratory Manual for
Dairy Technology Practical published by ICAR subcommittee on Dairy
education.

59
Indira Gandhi National Open University
School of Agriculture BPVI-015
Dairy Products-II

Diploma
in
Dairy Technology
(DDT)

PRACTICAL MANUAL
 Indira Gandhi
National Open University BPVI-015
School of Agriculture
Dairy Products-II

PRACTICAL MANUAL
Experiment 1
Preparation of Khoa 5
Experiment 2
Preparation of Gulabjamun 8
Experiment 3
Preparation of Peda 12
Experiment 4
Preparation of Burfi 15
Experiment 5
Preparation of Rabri 19
Experiment 6
Preparation of Kalakand and Milk Cake 23
Experiment 7
Preparation of Kheer 27
Experiment 8
Preparation of Chhana 30
Experiment 9
Preparation of Rasogolla 33
Experiment 10
Preparation of Sandesh 36
Experiment 11
Preparation of Rasmalai 39
Experiment 12
Preparation of Channa-Murki 42

Experiment 13
Preparation of Paneer 45
Experiment 14
Study of Vacuum Pan/Double Effect/Triple Effect of Evaporator 49
Experiment 15
Study Of manufacture of Spray Dried Milk Powder 51
Experiment 16
Preparation of Value Added Products From 53
Experiment 17
Visit of Dairy Product Manufacturing Plant 56
Programme Design Committee
Prof. H.P. Dikshit Prof. Panjab Singh
Ex-Vice Chancellor Vice Chancellor
IGNOU, New Delhi Banaras Hindu University, Banaras (U.P.)
Prof. S.C. Garg Shri A.N.P. Sinha
Acting-Vice Chancellor Former Additional Secretary
IGNOU, New Delhi Ministry of Food Processing Industries
Delhi

Ministry of Food Processing Industries, Milk Plant, Gwalior :

New Delhi : Shri M.E. Khan, Manager - Plant
• Mr. K.K. Maheshwary Operation
• Mr. R.K. Bansal, Consultant
• Mr. V.K. Dahiya, Tech. Officer (Milk Delhi Milk Scheme, Delhi :
Products) Shri Ashok Bansal, DGM

NDRI, Karnal, Haryana : CITA, New Delhi :

• Dr. S. Singh, JD (Academics) Shri Vijay Sardana
• Dr. S.P. Agrawala, Head (Dairy Engg.) Mahaan Protein, Mathura (U.P.) :
• Dr. Rajvir Singh, Head (Dairy Eco.) Dr. Ashwani Kumar Rathor, GM Technical
• Dr. K.L. Bhatia, Ex-Principal Scientist
• Dr. S.K. Tomar, Principal Scientist IGNOU, New Delhi (SOA Faculty
• Dr. B.D. Tiwari, Ex. Principal Scientist Members) :
• Dr. Dharam Pal, Principal Scientist • Dr. M.K. Salooja, Dy. Director
• Dr. A.A. Patel, Principal Scientist • Dr. M.C. Nair, Dy. Director
• Dr. Indrani Lahiri, Asstt. Director
Mother Dairy, Delhi : • Dr. P.L. Yadav, Sr. Consultant
Dr. P.N. Reddy, Former Quality Control • Dr. D.S. Khurdiya, Sr. Consultant
Manager • Sh. Jaya Raj, Sr. Consultant
• Sh. Rajesh Singh, Consultant
Programme Coordinators : Prof. Panjab Singh, Dr. M.K. Salooja and Dr. P.L. Yadav

Practical Manual Preparation Team

Writers : Dr. Dharam Pal Editors: Dr. P.L. Yadav,
Dr. S.K. Kanwaojia, Dr. B.D. Tiwari, Dr. J.S. Sindhu and
Dr. R. Balachandran and Dr. Vani Rai K. Dr. M.K.Salooja
Coordinators: Dr. M.K. Salooja, Dr. P.L. Yadav and Dr. J.S. Sindhu

Material Production
Mr. Rajiv Girdhar Word Processing – Mr. Bhim Singh
Section Officer (Publications)

November, 2006
© Indira Gandhi National Open University, 2006
ISBN-81-266-2639-9
All rights reserved. No part of this work may be reproduced in any form, by mimeograph or
any other means, without permission in writing from the Indira Gandhi National Open
University.
Further information on the Indira Gandhi National Open University courses may be ob-
tained from the university’s office at Maidan Garhi, New Delhi-110 068.
Printed and published on behalf of the Indira Gandhi National Open University, New Delhi, by
Director, School of Agriculture.
Laser typeset by : HD Computer Craft, EA 1/75, Inderpuri, New Delhi-110012.
Paper Used : Agrobased Environment Friendly
Printed at :
BPVI-015 DAIRY PRODUCTS-II
Dairy Products-II In the theory course we have studied different aspects such
as definition, composition, method of manufacturing, factors affecting quality,
packaging, shelf life and storage of heat desiccated products, acid and heat
coagulated products and concentrated and dried products. These aspects of
Khoa and Chhana based indigenous sweets have also been covered.

This practical course has been designed to undertake the practical exercises for
the manufacturing of the above mentioned products. In case of heat desiccated
products khoa, Rabri and Basaundi, will be prepared from milk. In addition to
that different khoa based sweets like peda, burfi, gulabjamun, kalakand and milk
cake will be prepared from the khoa. In case of heat and acid coagulated
products paneer and chhana will be prepared and the chhana thus obtained will
be used for the preparation of different chhana based sweets such as rasogulla,
sandesh, rasmalai and chhana murki.

Concentrated milk, dried milk and dairy whitener will be prepared in a dairy plant
or their preparation will be demonstrated to the students during plant visit.

Study Guide

The Practical Course involves 10 counselling sessions (4 hours each) of intense

work. During the counselling the guided and unguided experiments will be performed
by the students.

The practical evaluation shall be done under two components: (i) guided experiments
and (ii) unguided experiments. The guided experiments shall be performed during
the counseling sessions under the guidance of the counselors. The unguided
experiment shall be undertaken by the students in the last session. For unguided
experiments, student shall not be provided any guidance while performing the
experiments(s).

Both the components will be evaluated. The weight age of 70 per cent will be
assigned to guided experiments and 30 per cent is for unguided experiments.
Each experiment performed by the student would be evaluated. The student
performance would be assessed by the counselors covering various aspects like
manipulative skills, observation and their understanding of the basic concepts
related to experiment.

We would advice you to study the basic concepts given in course milk production
and quality of milk. This will enable you get maximum benefit from this practical
Course.

Laboratory Note Book

An important part of you scientific training is the maintenance of a complete and

up to date record of your laboratory work. For writing and reporting the
experimental data, notebook of 200 pages is required that is available in market.

You should prepare tables for recording the date as given in the manual. For,
each experiment, you should write down the type of sample, title of the experiments
to be conducted, observations and results.
Practical Manual— General Precautions for Practicals
Dairy Products-II
l Wear a lab coat or apron while performing the experiments.

l Wash your hands thoroughly with soap and water and then with potassium
permanganate solution before handling food.

l Plan your work carefully, read recipes and instruction properly.

l Assemble all required utensils before beginning, weigh or measure ingredients.

l Do not throw the waste food or any solid in the sinks.

l Clean the utensils thoroughly and wipe before you leave.

l Use the cutting board to keep hot utensils, never keep them on polished surface.

l Read the instruction of operator before use of equipment.

l Good quality buffalo milk should be taken for the manufacturing of khoa and
paneer.

l Good quality cow milk should be taken for the manufacturing of chhana.

l Row milk for the manufacturing of concentrated and dried milk should be of
high quality and should not have any developed acidity.

l Special care is needed for cleaning the equipment/floor.

l Quality of products should be tasted.

l Ingredient used should be of known quality and standard.

l Always draw a sample for analyses.

l While visiting the dairy plant making cheese and ice-cream you record all the
observation.

64