PRACTICAL MANUAL

MARKET MILK

DEPARTMENT OF DAIRY TECHNOLOGY

S.M.C. COLLEGE OF DAIRY SCIENCE

ANAND AGRICULTURAL UNIVERSITY

ANAND

Prepared by: Prof. Jarita Mallik & Prof. Dhinal Patel

Edited by: Dr. A. Jana & Dr. J.P. Prajapati

 Sheth M. C. College of Dairy Science

Anand Agricultural University, Anand-388110

Certificate

This is to certify that Mr./Ms._________________________________ of Second Semester B.Tech.

(Dairy Technology) class has attended ________out of_____ practical exercises conducted
in the subject of DT-1201: Market Milk during the semester. On the basis of his/her per-
formance and minimum practical exercises required to be completed, his/her work is
considered satisfactory /unsatisfactory and hence allowed to register for the semester
end practical examination.

Date: - - 20 Course Teacher Professor & Head

Dairy Technology Department
 INDEX
Teacher’s
Sr.
Date Title Page no. Presence
No.
Signature

1 Performing the platform tests – I 1

2 Performing the platform tests – II 7

Standardization of milk
3 14
(Pearson’s square method)

Standardization of milk (algebraic

4 17
method)

Performing the test to check the

5 20
efficiency of milk pasteurization

Assessing the quality of sterilized milk

6 22
by suitable tests

Determination of homogenization
7 24
efficiency of milk

Study of working of Can and Crate

8 27
washers

Working of a centrifugal cream

9 30
separator

10 Operation of a batch pasteurizer 34

11 Operation of H.T.S.T. pasteurizer 38

Operation of a plate Heat exchanger for

12 41
cooling

13 Preparation of recombined milk 45

14 Operation of UHT Processing plant 48

15 Preparation of recombined milk 53

Preparation of flavoured milk/drinks/

16 sterilized flavoured milk/chocolate
milk
EXERCISE NO. 1 DATE: ___________
TITLE: Performing the Platform tests – I

Objective: To get familiar with the different tests conducted on the platform in a dairy plant for acceptance of
raw milk.

Introduction

Market milk requires milk of a good quality from the standpoint of healthfulness. However, hygienic quality,
keeping quality and aesthetic background is basic requirement of any branch of the dairy industry. Initiative
should be taken by the milk producer to produce good quality of milk. To attain this, milk processor must
constantly check on the quality of the milk received and follow up, any defects or lapses in quality through,
educational work for the producers. In food industry, it is universally recognized that a high quality product
cannot be manufactured from low quality raw material.

Secondly, milk produced under unsanitary conditions and exposed to warm atmospheric temperature for long
period will have poor keeping quality and also show various defects due to excessive bacterial growth. Such
milk supply is likely to be found unsuitable for processing or for manufacture of milk products and if they are
bulked with other lots of milk the entire quality of milk may be spoiled. It is, therefore, necessary to detect
and weed out such milk supplies of unsatisfactory quality received at milk collection centers, dairies or milk
product factories. Any pronounced defect may be recognized by the flavour and odour of the milk but more
accurate tests of objective nature are required to be used for obtaining reliable information regarding the
quality of milk supplies and for judging their acceptability. The tests should be simple as well as rapid so as
to give results immediately since large number of consignments of milk which have to be screened for their
quality within a few minutes.

A number of platform tests are generally used for rapid assessment of the changes brought about, in the milk,
as a result of bacterial growth.

Tests

1. Organoleptic test (Smell & Taste)

2. Temperature

3. Acidity test

4. Sediment test

5. Clot-on-Boiling (C.O.B.) test

6. Alcohol test

7. Alizarin-Alcohol test

8. Resazurin Reduction test (RRT)

9. Methylene Blue Reduction test (MBRT)

10. Fat test by Gerber method

11. Lactometer Reading

1
1. Temperature of Milk

Temperature measurement of milk, especially in the case of chilled milk supplied from distant chilling centers,
renders a great help towards the judgment of the bacterial quality of milk at the chilling center which collects
milk from the round places. The milk is rapidly and immediately chilled to a temperature of about 5°C before
it reaches to main processing plant. During transit of milk from chilling center to main processing plant, the
temperature of milk may rise which leads to the growth of the micro flora of milk. This doubtlessly lowers the
bacteriological quality of milk.

Thus, keeping these in view, it requires that the milk for pasteurization should be delivered at the reception
dock of dairy plant within 2 hours of its drawing. The milk should be cooled immediately after it has been
drawn and must be maintained at or below this temperature till processing.

Procedure

1. Stir the milk thoroughly with the help of plunger.

2. Collect sample of milk in a beaker using a sampler.

3. Immediately measure the temperature of the milk using an accurate thermometer.

Interpretation

Temperature of milk around 5°C indicates that there is full proof insulation system provided to milk which has
restricted the heat transfer during transportation. Higher temperature of milk may be because of failure of
refrigeration, leakage in insulation system, longer time during transportation etc.

2. Acidity Test

Fresh milk does not contain lactic acid. The acidity of fresh milk is due to casein, albumin, globulin, CO2, citrates
and phosphates together with soluble calcium salts. The lactose present in milk is fermented upon bacterial
action. The fermentation products are responsible for increase in titratable acidity and subsequent souring of
milk. In general, average acidity of mixed milk varies from 0.15% to 0.16% LA.

Apparatus

Porcelain dishes, glass rods, pipette (10 ml), burette

Reagents

0.1 N NaOH solution, Phenolphthalein indicator (1 % alcoholic solution)

Principle: Determination of the acidity of milk by titration with 0.1 N solution of an alkali, such as NaOH, is
based upon the fact that a given volume of 0.1 N solution of an alkali will exactly, neutralize an equal volume
of 0.1 N solution of an acid.

Procedure

1. Measure 10 ml. of milk into a porcelain dish.

2. Add 3 to 4 drops of indicator.

3. Fill the burette with 0.1 N NaOH solution.

2
4. Slowly add 0.1 N NaOH from a burette, stirring the sample with a glass rod.

5. When the first definite and relatively permanent shade of pink colour has been reached, read the burette
to determine the ml of 0.1 N NaOH used.

6. Repeat the same for two three times for confirmation, tabulate the results and give comments.

Observations

Pipette :

Burette :

Indicator :

Colour change:

Burette reading

Sr. No. Burette reading Mean % L.A.

Initial Final Difference
I
II
III

Calculation

ml. of 0.1N alkali X 0.009 X 100

Acidity (as % Lactic acid) = --------------------------------------------
Volume of sample

3. Clot-on-Boiling (C.O.B.) Test

It is based on the fact that milk samples having high acidity, due to bacterial growth, are coagulated when
heated to boiling temperature. Samples of milk having poor stability due to disturbed salt balance also shows
signs of coagulation when heated to boiling, however, the acidity at which milk coagulates in such a test varies
greatly, depending upon the salt composition of milk.

Apparatus: Test tube, test tube holder, spirit lamp or gas flame or boiling water bath

Procedure

1. Collect a representative sample of milk from the container.

2. Take about 5 ml. of the milk in a clean test tube.

3. Place the test tube in a boiling water bath-for about 5 min or otherwise heat the milk by direct flame on
spirit lamp or on a gas flame till boiling.

4. Observe the clotting on the sides and bottom of the test tube.

5. The presence of such clots (curd particles) indicates positive test.

Interpretation: Positive test indicates high developed acidity or unbalanced salt concentration. Such milk
cannot be used for further processing.

4. Determination of Fat content of Milk

3
Dr. N. Gerber of Switzerland and Dr. Babcock of U.S.A. invented simple method of determining the fat content
of milk in the year 1892 and 1890 respectively. In India, Gerber’s method is most commonly used.

Materials

a) Milk butyrometers (0-10)

b) Rubber stoppers and butyrometer stand

c) 10.75 ml milk pipette

d) 10 ml & 1 ml Automatic tilt measures

e) Water bath (65°C)

f) Centrifuge

g) Gerber sulfuric acid (Sp. gr. 1.820-1.825)

h) Iso amyl alcohol (Sp.gr. 0.815 - 0.825)

Principle: Concentrated H2SO4 when mixed with milk in correct proportion digests the protein of milk turning
them into simpler substances which are deprived of the power of maintaining fat droplets in the emulsified
state. This enables the fat globules free and melted due to generation of heat and rise to the surface and forms
a single mass. The heat generated also reduces the viscosity of the mixture.

The second principle explains the separation and collection of fat particles. The content of the butyrometer
is a mixture of two fluids of different specific gravity viz., fat having specific gravity 0.90 and the acid mixture
having specific gravity 1.43 at the temperature attained. The specific gravity of the substances being different
in the centrifuge the greatest force is exerted on the heavier portion, which is in this case is the acid mixture.
In the butyrometer, therefore, which remain horizontal in the centrifuge the fat is collected near the centre and
the acid mixture is collected at its lower end, away from the centre.

Procedure

1. Take 10 ml of Gerber sulfuric acid into two milk butyrometers.

2. Mix the milk sample thoroughly by transferring it in another container 3 - 4 times. Allow it to stand for 3
min. to avoid air bubbles.

3. Take 10.75 ml milk and add to the butyrometer in which the acid has been taken previously, taking care
that the milk does not mix with the acid.

4. Take 1 ml of amyl alcohol and add to the butyrometer without wetting the neck.

5. Insert rubber stopper carefully, dissolve the curd by shaking at 45° angle and inverting the butyrometers
in the stand.

6. Place the milk butyrometers in a centrifugal machine and revolve it at speed of 1100 rpm for at least 3
minutes.

7. Temper the butyrometers in water bath for 5 min.

8. Take out the butyrometers and read the content of fat.

4
5. Determination of T.S. (Total solid) and Solids-Not-Fat (SNF) Using Lactometer

As a matter of convenience, the specific gravity of milk is measured usually with lactometer. The lactometer is
a hydrometer with a scale adapted to the limits of specific gravity of milk. It works on the principles that the
body floating in liquid sinks to such a level that it displaces a volume of liquid equal in weight of the floating
body. In liquid of low specific gravity the hydrometer sinks more than the liquid of higher specific gravity

Apparatus

a) Zeal lactometer

b) Thermometer

c) Cylinder

Procedure

1. Take a representative sample of milk.

2. Adjust the temperature of the sample as nearly as possible to that at which the lactometer is designed to
work (i.e. 84°F).

3. Heat milk to 45°C, keep at that temperature for 30 min and then cool to temperature at which lactometer
reading (LR) is to be taken. This will nullify Recknagel’s phenomenon.

4. If the temperature of milk is higher or lower than 84°F, a correction factor is to be applied. For higher
temperature than 84°F, 0.1 is added to the observe reading and for each degree Fahrenheit below, 0.1
is subtracted from the reading. The range of lactometer reading is 80°F to 90°F. Outside this range the
correction factor does not work satisfactory.

5. Place the milk sample in a tall cylinder and insert the lactometer, allow it to reach static position.

6. Take care that it does not touch the side of cylinder.

7. Note the lactometer reading carefully.

Precautions

1. Milk should not be examined until 2-3 h after milking.

2. Mix milk thoroughly before examining for specific gravity.

3. The lactometer must not touch the sides or bottom of the cylinder.

4. Record the temperature correctly.

5. Read the lactometer from the line in the scale which is in level with the surface of the milk and not turn
top of the meniscus.

6. Lactometer must be kept clean.

Calculation

1. Richmond formula (unrevised at 84°F):

T.S. = 0.25 CLR + 1.2 F + 0.14

5
 Revised, at 20°C :

T.S. = 0.25L + 1.21 F + 0.66

2. For buffalo milk

T.S. = 0.25L + 1.2 F + 0.55

3. Richmond’s formula = G/D + 1.191 F (Where, G= LR at 60°F, D= Specific gravity)

Where F = Fat content of milk, CLR = Corrected lactometer reading

4. Sharp and Heart TS= 1.237F + (268 Q/(Q + 1000)) (Where, Q= Quevenne LR at

30°C)

5. Watson T.S. = 1.33 F + (273 LR/(LR +1000))-0.4 (LR at 102°F)

Study Questions

1. Why milk should be chilled soon after drawing?

2. Even though there is presence of acid other than lactic acid, why is acidity of milk measured in terms
of lactic acid?

3. Show reaction taking place during titration of milk.

4. Differentiate between ‘natural acidity’ and ‘developed acidity’ of milk.

5. What may be the reasons for curdy and charred fat columns?

6. What may be the reasons for a positive C.O.B. test of milk?

7. Why is sulfuric acid preferred over other acids for Gerber fat test?

8. Why 10.75 ml milk is to be taken for Gerber fat test?

9. What precautions should be taken while performing Gerber fat test?

10. What is ‘Recknagel’ phenomenon?

11. Write specific gravity of different constituents of milk.

12. Why different formulas are used for calculating SNF of milk in various dairy plants?

6
EXERCISE NO. 2 DATE:_________

TITLE: Performing the Platform tests – II

Objective: To get familiar with the different tests conducted on the platform in a dairy plant for accepting the
raw milk.

1. Organoleptic Test

Milk consumers judge the quality of the product by the flavour and appearance of milk by the senses of smell
and taste. Therefore, organoleptic test is of obvious importance at a market milk plant. Each can of milk
should be carefully examined by the sense of smell before the milk is collected, those with objectionable
odours should be rejected. It is not practical to taste each can but in special cases, tasting is necessary. It is
desirable to verify one’s judgment by tasting in the case of bitter and certain weed flavours. The sense of smell
will not detect such flavours it is, therefore, necessary to taste the milk. An experienced person can pick out
such samples of milk with a fair degree of accuracy. Thus, this test involves visual observation, smelling and
tasting of milk.

Procedure

1. Open the cover/lid of the can.

2. Smell the milk immediately after opening the cover lid of the can so as to perceive any off flavour, before it
escapes out.

3. Stir the milk thoroughly while smelling to confirm the sensation of smell.

4. Note down the smell, colour and extent of contamination of extraneous matter.

5. Taste a small quantity of milk if required.

Note: The air space in the can will be laden with any odorous substances that may be present in the milk
and as a result, any off odour can be perceived most readily before this air has escaped by ventilation.

Interpretation: Milk sample giving any abnormal flavour like acidic, metallic, putrid, rancid, etc. and any
appearance of colour like reddish should be rejected or hold over for further examination.

2. Sediment Test

Visible foreign matter in milk is objectionable for several reasons. The presence of dirt is an objection, in
itself, but it is further more an indication of carelessness in handling which usually means a lack of sanitation.
Presence of particles of visible dirt usually means that a considerable amount of other foreign matter has
entered the milk but cannot be seen because it is in solution. The test is especially useful in educating producers
as to the need for cleanliness and as a general check on incoming milk at a collecting centre of processing plant.
Thus, sediment test present a simple rapid and quantitative means of indicating the cleanliness of milk with
respect to visible dirt. However, it need not necessarily indicate heavy bacterial contamination.

Apparatus: Sediment tester, White lintine cotton discs, Dipper for sampling from milk cans, Plunger

Procedure

A) Mixed Sample Method

1. Take 1 lit sample of milk from can after thorough mixing.

7
2. Filter the milk through a properly adjusted firm cotton lintine disc, held in hopper of the sediment tester
so that a filtration area of 1 1/8” diameter is exposed.

3. Dry the disc and note the amount of sediment present

4. Compare the sediment discs and interpret the results.

Note: If the fat is not uniformly distributed throughout the mass, it will tend to clog the sediment discs. The
colder the milk, the more difficult it will be to filter through the cotton discs. A temperature of milk
from 30-40° C facilitates filtration.

B) Off Bottom Method

1. Insert the sediment tester into an unstirred can of milk taking care not to agitate the milk unduly.

2. Sample approx. 500 ml of milk at level not more than 1/4” above the can bottom by simultaneously
raising the plunger and pushing the head of the tester once across the bottom of the can with a downward
movement of the plunger.

3. Force the milk through the cotton lintine disc with the std. 1 1/8” diameter filter area exposed.

4. Dry the disc and note the amount of sediments present

5. Compare the sediment discs and interpret the results.

Interpretation

Amount of Sediment Quality (grade) of milk

0.0 mg Excellent
0.2 mg Good
0.5 mg Fair
1.0 mg Bad
2.0 mg Very bad
Presence of appreciable sediment in milk indicates careless or unsanitary Dairy Farm practice.

3. Alcohol Test

The alcohol test determines the susceptibility of milk to coagulation due to developed acidity, disturbed salt
balance or high albumin-globulin content. The alcohol test determines the heat stability of milk. This test is of
importance in evaporated milk plants to detect milk which has a tendency to curdle during the sterilization
process. The colostrum, stripper milk and high in salt content, usually gives positive test.

Buffalo milk has been observed to be less stable than cow milk under the influence of alcohol. The lower
stability of buffalo milk has been ascribed to its higher soluble Ca content. The coagulation time with ethanol
decreases with rise in temperature and increases on dilution with water. Generally for bulk milk samples of
buffalo milk, 72-88% alcohol and for individual samples 64-92 % alcohol gives positive test.

Materials: Test tube, Alcohol (68.65 % by wt. or 75% by vol. or 0.867 g/ml density at 27°C)

Procedure

1. Take 5 ml of milk sample in the test tube.

2. Add an equal volume of Ethyl alcohol.

8
3. Mix the content by inverting the test tube.

4. Observe flakes or curd formation on the side of test tube.

Note: The temperature of milk and alcohol should be preferably 20°C.

Interpretation

1. Formation of flakes or curd on the sides of the test tube indicates the positive test, for presence of abnormal
milk.

2. No change in milk suggests normal or heat stable milk.

3. Large flakes indicate high acidity (> 0.2% LA) and instability to heat, due to other abnormal conditions.

4. Alizarin Alcohol Test

Adding alizarin along with alcohol test helps in finding out whether milk is acidic or alkaline. This indicator
gives a yellow or brownish colour in high acid milk, a yellowish brown or reddish brown colour in normal milk
and a brownish red (purple) to violet red in milk that is less acidic than normal milk. This test is normally for
the milk which is alkaline in nature and high in salt content.

Materials: Test tube, 0.2 % solution of alizarin in alcohol (68% by wt. or 75% by vol.)

Procedure
1. Take 5 ml. of milk in a test tube.
2. Add an equal volume of alizarin solution
3. Shake the contents thoroughly.
4. Observe the colour of the curd flakes formed.
Interpretation: The quality of milk is judged on the basis of the presence of curd flakes and colour of the
mixture.

Colour change to be noted

Presence of Interpretation about milk quality

Flakes and Colour
- ve, Pale Red Good, low acidity, satisfactory
+ ve, Pale Red Poor, sweet curdling, unsatisfactory
+ ve, Violet Poor, unsatisfactory
+ ve, Brown Poor, developed acidity, unsatisfactory
+ ve, Yellow Poor, developed acidity 0.2% L.A., unsatisfactory
OR

Colour Acidity (% LA)

Lilac Up to 0.14%
Brown Red 0.16% (0.14 - 0.17%)
Reddish Brown 0.2% (0.17 - 0.20%)
Yellowish Brown 0.24%
Brownish Yellow 0.28%
Yellow 0.36%

9
5. Ten Minutes Resazurin Test

Resazurin is an oxidation-reduction indicator. It is initially blue in colour and gets reduced in two stages.
First to a pink compound (resorufin) and then to a colourless compound (dihidro resorufin), as a result of
bacterial activity. The first stage of reduction is an irreversible change and second is reversible. In the course
of reduction of resazurin in milk, there will be series of colour changes which can be compared with standard
colour discs, in a lovibond comparator and expressed in terms of a standard resazurin disc number (0 to 6).
The time taken for the reduction of resazurin in milk to any particular stage of the colour change (disc. No.)
recorded at the end of any particular period (10 min) of incubation of the milk sample and the same is used
as criterion of bacterial activity in milk. Rapid reduction of the dye indicates high bacterial count and poor
keeping quality. Since resazurin is also affected by reducing activity of leucocytes cells present in mastitis milk
and late lactation milk, this test also helps in detecting such abnormal milks.

Materials

1. Water bath (37°C) 6. 10.0 ml & 1.0 ml pipette

2. Sterile test tubes 7. Beakers/ flasks

3. Sterilized rubber bungs 8. Samples of milk

4. Pair of forceps 9. Resazurin solution

5. Lovibond comparator with standard resazurin colour discs.

Principle: In this test, the milk sample containing resazurin solution is incubated at 37°C and the colour
changes recorded at the end of 10 min. are used for grading raw milk.

Procedure

1. Shake the sample of milk thoroughly. Pour 10 ml of the milk sample into two test tubes by means of a
sterile pipette.

2. Add 1 ml of Resazurin solution into one of the tubes with a sterile 1 ml pipette taking care that the pipette
does not come into contact with the milk.

3. With a pair of forceps, insert sterile rubber stoppers into the tubes so that they are completely closed (Use
sterile rubber stoppers only).

4. Inverse the tubes twice so as to mix the contents well and immediately transfer them to a water bath
maintained at 37°C.

5. At the end of 10 min., the tubes should be removed from the water bath, gently inversed once and the
colour is read in the comparator.

6. Tubes showing partial discolouration should not be inverted.

7. The milk tube to which Resazurin is not added is used as control and placed in the left slot of the comparator
to compensate for the natural colour of milk.

8. Revolve the Resazurin disc until the colour of the milk in the tube matches with one of the standard discs
in the comparator.

9. Record the disc readings and tabulate the results.

10
Observation Table

Particulars of Time of starting Resazurin disc No. Inference

milk samples at 10 min.

Interpretation

The following BIS standard is suggested as a guide for grading of raw milk supplies.

Resazurin disc No. at 10 min. Keeping Quality Remarks

period
6, 5 or 4 Satisfactory Receive the milk
3 ½ ,2 or 1 Doubtful Hold over for further examination
½ or 0 Unsatisfactory Reject the milk

6. Methylene Blue Reduction Test

This test is based on the principle that methylene blue (an oxidation- reduction dye or indicator) which is blue
in its oxidized state, is reduced to a colourless compound (Leuco form) as a result of the metabolic activities
of bacteria in milk. When a solution of methylene blue is added the organisms present in milk consume the
dissolved oxygen and lower the O-R potential to a level, when methylene blue and similar indicators are
reduced or decolourized. The time taken for the reduction of the dye (methylene blue reduction time) is
influenced by the number and types of bacteria present in milk. The greater the numbers of organisms present
in milk and greater their activity, more rapidly is the dye reduced.
The M.B.R. test is therefore, used for:
(a) Judging the hygienic quality of milk and grading raw milk supplies
(b) For assessing the probable quality of milk
(c) For detecting post pasteurization contamination in milk.
Materials
1. Water bath maintained at 37°C 5. Clock or watch
2. Sterile test tubes 6. Forceps, beakers and flasks
3. Sterilized rubber bungs 7. Methylene blue solution
4. 10 ml and 1 ml pipettes 8. Milk samples
Procedure
1. Thoroughly mix the samples of the milk.
2. Transfer 10 ml. of each sample of milk into a test tube.
3. Add 1 ml. of the methylene blue solution (0.005% strength) to the milk in the test tubes and replace the
cotton plugs with sterile rubber bungs using sterile forceps. While transferring methylene blue solution
care should be taken not to contaminate the pipette by touching the milk or otherwise a fresh pipette will
have to be used for transferring methylene blue solution to another tube.
4. Mix the dye and the milk by inverting the tubes twice.

11
5. Place the tubes in the water bath maintained at 37oC.
6. Observe the test tubes after every 30 min. and if there is no sign of reduction (decolourization) the tubes
are inverted once and returned to the water bath. If the decolorization has commenced the tubes should
not be inverted or shaken.
7. Continue the observations until the complete reduction of the dye (complete decolourization) occurs or
the formation of a persistent blue ring (0.5 mm) at the top.
8. Two control tubes, one containing 10 ml. of milk and 1 ml. of the methylene blue solution, after heating it
in boiling water for 3 minutes and another with 10 ml. of milk plus 1 ml. of tap water is also kept in water
bath. These are required for comparing the colour changes in experimental tubes.
9. 9. Record the times taken for reduction of methylene blue.
10. 10. Tabulate the results.
Observation Table

Time of Time at
Milk M.B.R. time
starting decolourization Inference
sample (h. min.)
(h. min.) (h. min.)
I
II

Interpretation

The following BIS criteria (IS-1479, Part 3, 1977) for Methylene Blue Reduction Time are suggested as a guide
for grading of raw milk supplies.

M.B.R. Time (h) Quality of milk

5 and above Very good
3 and 4 Good
1 and 2 Fair
0.5 and below Poor
Study Questions
1. What is the ideal taste of normal milk?

2. Enlist various off-flavours which may be experienced in raw milk.

3. Which test would you prefer out of resazurin reduction test and methylene blue reduction test for raw
milk quality? Why?

4. What is indicated by a positive alcohol test for milk?

5. Is there any relation between MBR time and microbial population in milk? When such result may give
‘false positive’ indication?

6. If sediment test for raw milk gives result exceeding 0.5 mg, what does it infer?

7. What is the difference in the inference given by alcohol test and alizarin alcohol test?

8. Which platform test is of more significance in UHT processing of milk? Why?

12
EXERCISE NO. 3 DATE: _________

TITLE: Standardization of milk (Pearson’s square method)

Objectives

1. To get familiar with the various methods used for standardization of milk

2. To standardize milk rapidly when focusing on one milk constituent

Introduction

Standardization of milk refers to the adjustment, i.e. raising or lowering, of the fat and/or solids-not-fat
percentages of milk to a desired value, so as to conform to the legal or other requirements prescribed. Milk is
standardized by the addition of milk or cream with a higher or lower fat percentage than that of the material
to be standardized; sometimes the addition of skim milk will fulfill the purpose. Standardization method may
involve batch processing or continuous processing.

In batch processing Pearson’s square method may be used to calculate the volumes of whole milk and skim
milk/cream needed and the two can be simply mixed to yield the required product. Continuous standardization
system consists of a cream separator with in-line densitometer at the skim milk and cream outlets. Whole milk
is fed to the separator and, with careful control of the cream and skim milk fat contents and measurements of
the flow rates of the two streams, cream can be metered back into the skim milk stream to yield standardized
milk with the required fat level.

Procedure

To solve the standardization problem, it is necessary to find the relative amounts of the original material and
the standardizing material to be mixed together to give a product with the desired fat content. Once these
relative amounts/proportions have been determined, it is easy to calculate the exact amount of each which
must be mixed together to give a certain weight of the finished product or the weight of milk or cream.

There are two calculation methods by which we can solve the standardization problems.

(1) Pearson’s Square Method

(2) Algaebraic Method

Pearson’s Square Method

1. Draw a square and place in the centre of it the fat percentage desired.

2. Place at the left-hand corners of the square the fat percentage of the materials to be mixed.

3. Subtract the number in the centre from the larger number at the left-hand side of the square and place
the remainder at the diagonally opposite right-hand corner.

4. Subtract the smaller number on the left-hand side from the number in the centre and place the
remainder at the diagonally opposite right-hand corner.

5. The numbers on the right-hand side now represent the number of parts of each of the original materials
that must be blended to make a product with a fat test given by the number in the middle of the square.

13
 6. The number at the upper right-hand corner refers to the parts of material whose fat test was placed at
the upper left corner.

7. The number at the lower right corner refers to the parts of material whose fat test was placed at the
lower left corner.

8. Add the numbers on the right hand side. The sum thus obtained will represent the parts of the finished
product, with the fat test given by the number obtained in the middle of the square.

Fat % in first raw material A (B – C) or (C – B) = D parts of

raw material A

C +

Fat % in second raw material B (A – C) or (C – A) = E parts of

raw material B
----------------------------------------------
(D + E) = F parts of standardized
milk of desired composition

Alternatively, to calculate the amount of each type of raw material required, for example, per batch of a 100 lit
of standardized milk:

(B – C)
A = ------------- X 100
F

(A – C)
B = -------------- X 100
F

Note: Pearson’s square method can be used to standardize only one constituent of milk at a time, i.e. either fat
or SNF.

Numerical 1. How much quantities of full cream milk (6.0% fat) and skim milk (0.1% fat) are required to
produce 5000 kg of standardized milk having 4.5% fat?

6.0 4.5 – 0.1 = 4.4

+
4.5

0.1 6.0 – 4.5 = 1.5

-------------------------------------
5.9

The amount of full cream milk required

4.4 X 5000
= ------------------ = 3728.81 kg
5.9

14
The amount of skim milk required
1.5 X 5000
= ------------------ = 1271.19 kg
5.9
Standardized milk (4.5% fat) = Full cream milk (6.0% fat) + Skim milk (0.1% fat)

= 3728.81 + 1271.19 = 5000.00 kg

Although the above calculation does not take into consideration the amount of solids-not-fat present in the full
cream milk, the accuracy is sufficient for most practical purposes. However, as an additional check, the final
composition of standardized milk can be calculated as follows:

Ingredient Quantity (kg) %Fat kg fat

6.0 X 3728.82
Full cream milk 3728.82 6.0 ------------------ = 223.72
100
0.1 X 1271.19
Skim milk 1271.19 0.1 ------------------ = 1.27
100
Total calculated 5000.00 -- 223.72 + 1.27 = 224.99
4.5 X 5000
Total desired 5000.00 4.5 -------------- = 225
100

15
EXERCISE NO. 4 DATE:___________

TITLE: Standardization of milk (Algaebraic method)

Objectives

1. To get familiar with the various methods used for standardization of milk

2. To make the processed milk conform to the legal standards

3. To keep safety margin for milk constituents when selling market milk.

Introduction

Standardization of milk refers to the adjustment, i.e. raising or lowering, of the fat and/or solids-not-fat
percentages of milk to a desired value, so as to conform to the legal or other requirements prescribed. Milk is
standardized by the addition of milk or cream with a higher or lower fat percentage than that of the material
to be standardized; sometimes the addition of skim milk will fulfill the purpose. Standardization method may
involve batch processing or continuous processing.

Continuous standardization system consists of a cream separator with in-line densitometer at the skim milk
and cream outlets. Whole milk is fed to the separator and, with careful control of the cream and skim milk fat
contents and measurements of the flow rates of the two streams, cream can be metered back into the skim
milk stream to yield standardized milk with the required fat level.

Addition of SMP (over and above whole milk) is especially required when SNF content is to be raised from say
8.5% to 9.0% as in case of Double Toned Milk.

Procedure

To solve the standardization problem, it is necessary to find the relative amounts of the original material and
the standardizing material to be mixed together to give a product with the desired fat content. Once these
relative amounts/proportions have been determined, it is easy to calculate the exact amount of each which
must be mixed together to give a certain weight of the finished product or the weight of milk or cream.

Algaebraic Method

This method of calculation takes into consideration all the constituents of milk and raw materials used for
standardization purpose.

1. Tabulate all the available ingredients, their %fat and %SNF

2. Assume quantities of each ingredient which are going to be used for standardization purpose.

3. Make necessary appropriate assumptions required during standardization calculations.

4. Form quantity equation, fat equation and SNF equation.

5. Solve the above three equations and find out quantity of each ingredients to obtain standardized milk.

6. Prepare proof sheet to check, whether calculations are correct or not.

16
e.g.

Prepare 10,000 kg standardized milk from whole milk having 6.0% fat and 9.0% SNF and skim milk. Make
necessary appropriate assumptions wherever necessary.

Ingredients Table

Quantity
Ingredient %Fat %SNF
(kg)
Buffalo milk X 6.0 9.0
Skim milk Y 0.1 9.56
Water Z - -
Standardized milk 10,000 4.6 8.6

Serum of skim milk X SNF of whole milk

%SNF of skim milk = ---------------------------------------------------------
Serum of whole milk
(100 – 0.1) X 9.0
= ------------------------ = (99.9 x 9)/94
(100 – 6.0

= 9.56%

Assumptions

1. Skim milk has 0.1% fat and has been separated from the same whole milk.

2. Water is to be added. Potable water is available in plenty.

3. Safety margin of 0.1% fat and 0.1 % SNF is to be considered for standardized milk (i.e. 4.6% fat, 8.6%
SNF)

Calculations

Quantity Equation

Quantity of whole milk + Quantity of skim milk + Quantity of water = 10,000

X + Y + Z = 10,000 ------------------------------------------------- (1)

Fat Equation

kg fat in whole milk + kg fat in skim milk = kg fat in standardized milk

6.0 X + 0.1 Y + 0 =
4.6 x 10,000

100 100 100

6 X + 0.1 Y = 46,000 -------------------------------------------------(2)

17
SNF Equation

kg SNF in whole milk + kg SNF in skim milk = kg SNF in standardized milk

9.0 X + 9.56 Y + 0 =
8.6 x 10,000
100 100 100

9 X + 9.56 Y = 86,000 ----------------------------------------------(3)

Solve the equation (2) & (3)

Multiply equation (2) by 9 and equation (3) by 6 and then solve the equations

54 X + 0.9 Y = 414000

54 X + 57.36 Y = 516000
__________________
- 56.46 Y = – 102000
Y = 1806.58 kg

Put value of Y in equation (3) and get the value of X

9 X + 9.56 (1806.58) = 86000

X = 7636.56 kg

Put value of X and Y in equation (1) and derive the value of Z

7636.56 + 1806.58 + Z = 10000

Z = 556.86 kg

Therefore, the raw material required

Whole milk : 7636.56 kg

Skim milk : 1806.58 kg

Water : 556.86 kg

Total :10000.00 kg

Proof Sheet

Proof sheet from the above weights of raw materials can be made to confirm the calculations.

Ingredient Quantity %Fat kg fat %SNF kg SNF

(kg)
Whole milk 7636.56 6.0 6.0 X 7636.56 9.0 9.0 X 7636.56
------------------ = 458.19 ------------------ = 687.29
100 100
Skim milk 1806.58 0.1 0.1 X 1806.58 9.56 9.56 X 1806.58
------------------ = 1.81 ------------------ = 172.71
100 100
Water 556.86 0 0 0 0

18
Total calcu- 10000.00 -- 458.19 + 1.81 = 460 -- 687.29 + 172.71 = 860
lated
Total desired 10000.00 4.6 4.6 X 10000 8.6 X 10000
------------------ = 460 ------------------ = 860
100 100

19
EXERCISE NO. 5 DATE: ____________

TITLE: Performing the test to check the efficiency of milk pasteurization

Objective: Proper pasteurization of milk ensures public health safety hence performing test to check the
efficacy of milk pasteurization is of great significance in dairy industry

Introduction

The test is used to judge the efficiency of pasteurization of milk. According to the FSSA specifications
Pasteurization means “a microbicidal heat treatment aimed at reducing the number of any pathogenic micro-
organisms in milk and liquid milk products, if present, to a level at which they do not constitute a significant
health hazard. Pasteurization conditions shall be designed to effectively destroy the organisms Mycobacterium
tuberculosis and Coxiella burnetti”. To test whether the heat treatment by either of these methods was properly
carried out, the treated milk is subjected to the alkaline phosphatase test which helps to indicate the presence
or absence of alkaline phosphatase enzyme. Alkaline phosphatase enzyme present in milk is destroyed by
just above the same heat treatment necessary for the destruction of Mycobacterium tuberculosis or Coxiella
burnetti, the most heat resistant pathogens likely to be present in milk. These are the causative organisms for
tuberculosis and Q-fever, respectively. When heat transfer to milk is insufficient to inactivate the enzyme, it
remains active and will liberate phenol from the disodium phenyl phosphate in a buffered solution at a pH of
about 9.5. The presence of free phenol is determined by a colorimetric test. The sample of pasteurized milk
shall be tested within 48 h after pasteurization. The sample shall be stored at a temperature not exceeding 5°C.

Apparatus

1. Lovibond all-purpose comparator

2. Standard discs: having 0, 6, 10, 18, 42 or 0, 6, 10, 14, 18, 25, 42 readings

3. Test tubes: 15 X 1.9 mm, with ring at 10 ml fitted with rubber stoppers

Reagents

1. Buffer solution: Dissolve 3.5 g of sodium carbonate and 1.5g of sodium bicarbonate in 1 lit of water

2. Substrate: Disodium p-nitrophenyl phosphate (min. 95% purity)

3. Buffer substrate (buffer solution comprising of 0.75g anhydrous sodium carbonate and l.75g
Sodium bicarbonate in 500 ml distilled water): Transfer 0.15 g of the substrate (di-sodium para-
nitrophenylphosphate) into 100 ml measuring cylinder or stoppered graduated flask and make up to
the mark with the buffer solution. The solution should not be stored for long periods but may normally
be kept in a refrigerator for up to one week.

Principle

In this test, milk is added to a suitably buffer solution of p-nitro phenyl phosphate which is readily hydrolyzed
by the enzyme alkaline phosphatase (present in raw milk) to liberate p-nitrophenol which is yellow in alkaline
solution (pH 9.5). The phenol liberated is also measured photometrically.

20
Procedure

1. Fill 10 ml of the buffer substrate solution into a test tube and warm up to 37°C in a water bath.

2. Add 2 ml of milk to be tested into the test tube containing buffer substrate solution, close the test tube
with rubber stopper and invert to mix.

3. Prepare blank from boiled milk in the same way as above.

4. Incubate both the tubes at 37°C.

5. Read the yellow colour after 30 min, return it to the water bath and take a second reading after
incubation for further 90 min.

6. The yellow colour is read as unit numbers in Lovibond all-purpose comparator using a standard disc.

Interpretation

Disc reading after 30 min incubation Interpretation

0 or trace Properly pasteurized
6 Doubtful
10 or above Under pasteurized
Note: The 30 min test will reveal any serious fault in pasteurization, but to enable minor errors to be detected,
readings shall be taken after further incubation for 90 min.

Disc reading after 2 h incubation Interpretation

0 or 10 Properly pasteurized
10 or above Under pasteurized
Study Questions

1. What may be the reasons for positive alkaline phosphatase test in pasteurized milk?

2. What is the relevance of phosphatase enzyme in milk system? Why acid phosphatase is not considered
for the test for efficiency of milk pasteurization?

21
EXERCISE NO. 6 DATE: ____________

TITLE: Assessing the quality of sterilized milk by suitable tests

Objective: To check the efficacy of milk sterilization to ensure attaining expected shelf life of milk at ambient
temperature

1. Turbidity Test

When milk is heated to sterilizing temperatures (104 to 110°C for 20 to 40 min), the albumin completely gets
precipitated. The test is performed by adding sufficient ammonium sulphate to precipitate other substances,
such as casein, filtering the mixture of milk and ammonium sulphate, and heating the filtrate. If milk has not
been heated to 100°C for at least a short time, the albumin remaining in solution will be revealed by turbidity
in the heated filtrate.

Reagent: Ammonium sulphate

Apparatus & Materials

1. Whatman filter paper No.42 or equivalent (12.5 cm diameter)

2. Erlenmeyer flask

3. Glass test tube

4. Water bath

Procedure

1. Weigh accurately 4 g of ammonium sulphate and add it to a conical flask.

2. Measure 20 ml sample and pour into the conical flask containing ammonium sulphate.

3. Mix properly for about 1 min to ensure that ammonium sulphate is dissolved.

4. Leave for not less than 5 min and then filter through Whatman filter paper No. 42 or equivalent into a
test tube.

5. When not less than 5 ml of a clear filtrate is collected, place the tube in a beaker of water, which is kept
boiling.

6. Keep it there for 5 min.

7. Transfer the tube to a beaker of cold water

8. When the tube is cool, examine the contents for turbidity by moving it before the normal daylight, or
under electronic lamp.

22
Interpretation

Milk which does not show any sign of turbidity in the test is considered to be satisfactorily sterilized. Even a
slight turbidity would indicate insufficient heat treatment meted out to milk during sterilization processing.

2. Determination of Creaming Index

Creaming index is an indication of good homogenization. Sterilized milk may be graded as under for the quality
of homogenization.

Apparatus: Glass centrifuge tubes, Centrifuge, Pipettes and beakers, Gerber fat testing kit

Procedure

1. Place 50 ml of milk at 20°C in each centrifuge tube. Centrifuge them for 15 min at 1000 rpm.

2. Using a separate pipette, carefully take 5 ml of the cream that adheres to walls from the upper part of
each of the three tubes, and transfer into a separate container (sample II). The lower part is sample I.

3. Analyze the fat content of the sample I and II by the Gerber method taking all the precautions required
to be taken for homogenized milk, i.e. heating the sample at 65°C for 5 min in water bath after each
centrifugation before taking the reading till identical readings are obtained.

Calculation

A–B
Creaming Index = ---------- X 100
B

Where, A = Fat content of the sample II (Fat content of top 10% of volume)

B = Fat content of the sample I (Fat content of remaining 90% volume of sample)

Interpretation

Efficiency of Homogenization Creaming Index

Excellent Up to 10
Good 11 to 20
Fair 21 to 30
Bad Over 30
Study Questions
1. Define ‘Sterilized milk’ as per FSSA.
2. What may be the reasons for a positive turbidity test?
3. What is indicated by a positive ‘turbidity test’ in case of sterilized milk sample?
4. What may be the reason for higher creaming index in homogenized milk?
5. What is an alternative test for creaming index for sterilized milk? How is it performed?
6. Why special care is to be taken for performing fat determination in case of homogenized milk?
7. Why is Creaming Index performed for ‘Sterilized milk’?

23
EXERCISE NO. 7 DATE:_________

TITLE: Determination of homogenization efficiency of milk

Objective

To check the efficiency of milk homogenization

Introduction

There are two methods to assess the efficiency of milk homogenization. (i) Farrall Index using microscope
method and (ii) Centrifugation of milk according to United States Public Health Services (USPHS) method.

USPHS method

The United States Public Health Service (USPHS) defines homogenized milk as milk which has been treated in
such manner as to ensure break-up of fat globules to such an extent that after 48 h quiescent (resting) storage,
no visible cream separation occurs on the milk. The fat percentage of the top 100 ml of milk in quart (946.33
ml) bottle, or of proportionate volumes in containers of other size does not differ by more than 10% of itself
from the fat percentage of the remaining milk determined after thorough mixing.

According to the above definition, if the top milk in the quart bottle contains 4.0% fat, the remainder of the
milk must have at least 3.60% fat. The difference, 0.4%, is 10% of the figure 4.0.

Apparatus

a. Fat testing kit, glass wares and reagents

b. Graduated cylinder for homogenized milk

Procedure

1. Collect the homogenized milk sample in the finished package and after proper agitation store the
sample at a temperature between 4 to 8°C and hold in a quiescent state for 48 h.

Note: When homogenized milk samples are stored for more than 3 h. after filling, it will be advisable to
agitate by pouring the sample from one bottle to another, 4-5 times. When samples are stored within
3 h. of filling time, sufficient mixing of the bottle contents may be done by slowly inverting the bottle
8-10 times.

2. After the 48 h, carefully remove bottle cap and pass a stiff wire around the inner surface of the bottle
neck to loosen any adhering butter fat.

3. Observe critically for any visible sign of cream separation or cream plug. Remove 100 ml milk from one
liter sample (proportionate amount from samples of other sizes) by pouring directly into the beaker
or by the suction method.

4. Thoroughly mix the 100 ml portion by pouring 3 or 4 times from one vessel to another, and proceed
for fat test for homogenized milk.

24
 5. Repeat this process with the remainder of the homogenized milk sample.

Calculation

A–B
USPHS Index (%)= ---------- X 100
B

Where, A= %fat obtained from top portion of centrifuged milk

B= %fat obtained from bottom portion of centrifuged milk

II. Farrall Index method

Apparatus & Materials: Light Microscope, Stage and ocular micrometer, cover slip, Distilled water, glycerine,
milk sample

Procedure

1. Place the stage and occular micrometer in their appropriate places on the microscope and find out least
count, i.e. which division of the stage micrometer coincides with the division of occular micrometer
keeping the zeroes of both coinciding.

2. Dilute the sample to be tested with 30-35% glycerine in water so that the sample contains 0.1 to 0.2%
fat. In case of milk dilute 1 ml of milk with 25 ml of glycerine in water solution.

3. Transfer a drop of the diluted sample on a clean slide and place a coverslip. Put slide in refrigerator
deep freeze for 10-15 min so as to get the smear frozen.

4. Observe under lens (100X) of the microscope and determine the size of fat globule by observing
numbers of divisions of ocular are covered by individual fat globule. Multiply this with least count.

5. Examine five randomly selected fields and count the globules larger than 2 µ and record the number
of globules in each size group. Multiply the number of globules in each size range by corresponding K
factor.

Note: K-factor is the ratio of the volume of average size globule to the volume of a globule of 2 µ sizes diameter.
The multiplication product of K-factor and fat globule size is called K-total and the sum of K-total of different
size ranges is known as homogenization index. Index lower than 5 indicates excellent homogenization efficacy.

Observations

Size of fat globule (μm) K-factor Sample K-total

2.0-2.5 1.4
2.5-3.0 2.6
3.0-4.0 5.4
4.0-5.0 11.4

25
 5.0-6.0 21.0
6.0-7.0 34.0
7.0-8.0 53.0
Sum of K-total

k-factor = (Average size of fat globule)3/(2)3

For instance, for size range 2.0-2.5 it will be (2.25)3/8 = 1.42

Study Questions

1. Why glycerine is used for dilution of milk for determination of fat globule size?

2. What is the range of fat globule size for normal milk?

3. If homogenization is not done efficiently, what would be the repercussions on the processed market
milk?

26
EXERCISE NO. 8 DATE: _________

TITLE: Study of operation of Can and Crate washers

Introduction

For small scale dairy plants, milk is received and handled in Aluminium or even Stainless steel cans (20, 40 l
capacity). After dumping the milk in the weighing tank or reception dock at dairy plant, the soiled cans needs
to be cleaned, sterilized and even dried for reuse. The typical seven sections in a Rotary can washer are Pre-
rinse water, Draining tank, Detergent tank, detergent draining tank, hot water rinse and hot air blower. The
cans get thoroughly washed, sterilized and finally dried before coming out of the Can washer.

The dispatch and transportation of market milk, dahi and other such packed milk products are carried out
through crates in dairy industry. The soiled plastic crates are washed in a crate washer for reuse purpose.
Commonly used crate washers in dairy industry are straight through conveyor type, which uses high jet
pressure technique for efficient cleaning process. The crates are conveyed automatically by conveyor chain
fitted on stainless steel fabricated frame. The crates pass through specially designed High Pressure Water Jet
Nozzles having accurate spray angle for washing. The high pressure is generated by a high pressure pump
driven through electric motor and mounted close to conveyor.

Objectives

1. To get familiar with the operation of a Can/Crate Washer

2. To ensure that the milk procured is not contaminated by the Can and distribution of milk (small scale) can
be carried out in safe conditions.

Requirements

Milk cans/crates, detergents, filter, brush

Operation of Rotary type Can washer

Note: General operational procedures are identical for can and crate washer.

1. Drain out the water by opening drain valves (detergent water tank) and see that all jets are in working
condition.

2. Fill the hot water tank: Adjust the rotating table in such a way that there will not be any jetting in the
pre-rinse section. Then open the well water valve and open tap for hot water till overflow. After this
stop well water valve and tap for hot water.

3. Fill the detergent tank: Take 40 liters water in 3 cans and dissolve required detergents (shown below)
of required strength. Filter and pour this detergent solution directly in the tank by adjusting the outside
cover of the rotating table or by pouring it through soda box. Water can also be filled in the tank as
described for hot water tank filling.

4. Open main steam valve and then steam valves on panel, both for detergent tank as well as for hot water
tank, until the desired temperatures are achieved in both tanks.

5. Start the table to rotate. Put a can and a lid.

6. Put on water valve for pre-rinse section.

27
 7. Start detergent jetting and simultaneous operation of can washing.

Stopping the can washer

1. Stop water valve for the pre-rinse section.

2. Stop detergent jetting by stopping detergent motor-pump.

3. Close main steam valve.

4. Stop rotating table.

After washing all the cans check the efficiency of can washer by observing each can. They should be free from
milk particles, dust particles, specks, etc. They should be free from off odour and water droplets.

Crate washer (Straight-through type)

The plastic crates which are used for milk and Dahi pouch packing, require more vigorous and intensive
cleaning due to the solid walls and moulded recesses which have the tendency to retain solids. Generally
straight through type crate washer are available. In that crates are passing through one section to anther in
straight direction. These sections are depending on the requirement of plant quality we required for cleaning.
High Pressure Crate washer has been successfully working in various industries. The crates/trays are washed
thoroughly by high pressure water jetting. There is no requirement of steam, detergent, chemicals etc. Thus
there is saving of cost & energy as compared to conventional crate washer.

General Arrangement & Operation of high pressure jetting system

The crates/ trays are conveyed automatically by conveyor chain fitted on stainless steel fabricated frame. The
crates/trays pass through specially designed High Pressure Water Jet Nozzles having accurate spray angle for
washing. The high pressure is generated by a high pressure pump driven through electric motor & mounted
close to conveyor.

Advantages of high pressure jetting system

1. High pressure jetting system for efficient cleaning

2. Fully automatic & continuous duty

3. Very compact and easy to install

4. Ensures optimum cleaning in the fastest possible time

5. Compact design for space saving

6. Time and man power saving

7. No need of steam, chemicals, detergent etc

8. Easy for operation and maintenance

9. Special cleaning system can be designed for higher pressure

OBSERVATION CHART FOR CAN / CRATE WASHER

I. Particulars of the equipment

1. Make:

28
 2. Type:

3. Rated capacity:

4. Total number of sections :

5. Capacity of detergent tank:

6. Capacity of hot water tank:

II. Detergents

Type of chemicals Quantity in 120 lit. water

a. Sodium carbonate 700 g
b. Sodium hexa meta phosphate 200 g
c. Sodium meta silicate 1100 g
d. Sodium sulphate 480 g
Active alkalinity of detergent solution

Prior to its operation:

After operation:

III. Operation

1. Temperature Records:

Pre-rinse water:

Detergent solution:

Hot water (Tank):

Hot water (Jetting i.e. sterile rinse):

Steaming:

Hot air:

2. Time can washing started:

3. Time can washing completed:

4. Total time for can-washing:

5. Total number of can washed:

6. Actual capacity of can washer:

IV. Checking the efficiency of cleaning

1. Presence of water droplets:

2. Presence of milk soil:

3. Presence of extraneous particles :

29
 4. Smell (should not be able to perceive any off odour) :

Study Questions

1. Can you name other type of Can Washer, besides Rotary Can Washer?

2. Enlist various detergents that are employed in can and crate washer, along with their functions.

3. Can we use NaOH as an alkali in Can Washer? Why?

30
EXERCISE NO. 9 DATE: _________

TITLE: Operation of a centrifugal cream separator

Objectives

1. To get familiar with the different parts of an open type Cream-separator.

2. To understand the function of different parts of the Cream separator.

3. To study the factors affecting skimming efficiency

Materials & Apparatus: An open-discharge type Cream-separator assembly, spanner, milk pre-heater, filter,
milk cans, containers, etc.

Procedure

1. Dismantle the separator and arrange the parts as follows

a) Supply can with faucet

b) Float and regulating cover.

c) Cream spout and skim milk spout

d) Separator bowl-Bowl Body including spindle.

2. With the help of the spanner loosen the bowl-nut and arrange the bowl parts as follow

a) Top disc or dividing disc

b) Intermediate discs

c) Bottom disc

d) Milk distributor

e) Rubber ring or Gasket

f) Bowl-body or bowl-base or bowl-frame

3. Assembling before separation: All parts should be thoroughly cleaned and sanitized.

a) Place the rubber ring in its groove in the bowl body and press it down carefully.

b) Fit the distributor in the bowl-body pressing it down well. Take care that the holes in the flange
of the distributor fit over the guide pin in the bowl body.

c) Place the bottom-disc, which is thicker than other discs and caulked (i.e. rivets) on both the
sides on the distributor and then put the intermediate discs. The centre hole of the disc is
provided with a semi-circular mark which should be turned against the broadest plane part of
the distributor.

d) Put on the top disc and bowl-hood. See that the guide pin on the bowl cover fits in the slit
provided in the bowl.

31
 e) Screw on the bowl-nut and tight it firmly with help of bowl spanner. The bowl is well tightened
when the marks on the bowl-nut and bowl body are opposite to each other.

f) Put the bowl carefully on the bowl-spindle. The metal strip provided in the bowl base bottom
must be inserted in the slit provided on the shaft.

g) Place the skim milk and cream spouts and press them down carefully. Make sure that bowl
rotates freely. Put the float into the regulating-cover and then place the supply can on its holder.
Press down the supply can firmly.

4. Cream fat regulation: If thinner cream is desired then screw out the cream-screw. If on the other hand,
thicker cream is desired, screw in the cream-screw.

5. Separation

a) Flush out 10-20 l. of hot (85°C) water through both the outlets of the separator. Adjust the speed
of the bowl accordingly.

b) It is advisable to separate the milk soon after milking. Normally milk should be heated up to about
40-50°C.

c) Weigh the milk to be separated and take a representative sample for fat testing.

d) After all the water has run out, pour the strained milk into the supply can. Note the time separation
started and stopped.

e) Receive cream and skim milk in clean, sanitized and dry cans of known tare weight.

f) When all milk has been separated shut off the motor. Pour about 5 lit. of skim-milk or hot-water
into the supply can so that all cream will be washed out of the bowl.

g) Allow the bowl to run down to standstill by itself. Do not take off the cover until the bowl has
stopped revolving.

h) Find out the net-weight of cream and skim milk obtained. Take sample of both cream and skim
milk for fat testing.

6. Cleaning after separation

Immediately after each separation, all parts that have come into contact with milk should be taken
apart and cleaned.

a) Lift off or turn a side the supply can and remove the covers by turning them round. Never
remove them by forcing upward.

b) Lift the bowl out of the frame and empty it.

c) Take the bowl apart and wash the bowl parts, supply-can, float and covers with luke-warm
water and then thoroughly with warm cleaning solution (washing soda, Tri Sodium Phosphate,
teepol (0.1 %) made into paste) using good plastic brush (avoid use of wire brushes) for
scrubbing.

d) After cleaning rinse immediately all parts in clean hot water and allow them to dry. Leave the
discs spread on the washing bow. Rinse the rubber ring in warm-water and be careful not to
stretch or damage it.

32
 e) Do not assemble the separator until it is to be used again.

Precautions: Use a rubber mat to keep the dismantled parts of cream separator for cleaning purpose.

Study Questions

1. Draw sketch of various parts of cream separator.

2. Write possible causes and remedial measures under the following conditions:

a) the separator does not skim satisfactorily

b) milk drips from the waste milk tube

c) cream separator runs with a noise

3. Explain the functioning of the cream screw.

4. What is the effect of following during separation?

a) temperature of milk

b) feed flow of milk

c) level of dust, dirt, foreign matters etc. in the milk

d) Speed (rpm) of separator

33
 OBSERVATION CHART FOR CREAM SEPARATION

I. Particulars of Cream separator

1. Type:

2. Make:

3. Rated capacity:

4. Actual capacity:

5. No. of discs:

6. Speed of the bowl:

II. Particulars of milk

1. Type:

2. Quantity:

3. % Fat:

4. % Acidity:

5. Temperature:

III. Operation

1. Time of flushing the separator with scalding water:

2. Temperature of milk (during separation):

3. Quantity of cream:

4. Quantity of skim milk:

5. Quantity of separator slime:

6. Quantity of whole milk used for flushing cream:

7. Position of cream screw during separation:

8. Handling losses:

IV. Efficiency of cream separation

1. Fat % in cream:

2. Total kg fat in cream:

3. Fat % of skim milk:

4. Total kg fat in skim milk:

5. Per cent fat recovery in cream:

6. Per cent fat lost in skim milk:

34
EXERCISE NO. 10 DATE: ___________

TITLE: Operation of a Batch Pasteurizer

Objectives

1. To study the cleaning and sterilization of the batch pasteurizer.

2. To get familiar with the different parts of the batch pasteurizer.

3. To ensure safety of milk and to prolong the keeping quality of milk without marked effect on its flavour,
food value or physico-chemical properties.

Definition of Pasteurization as per FSSA

Pasteurization, when used in association with milk, shall be taken to refer to the typical process of heating every
particle of milk to at least 63°C and holding at such temperature continuously for at least 30 min or heating it
to at least 72°C and holding at such temperature continuously for at least 15 sec., or any other temperature-
time combination, sufficient to give a microbicidal effect equivalent to the above defined temperature-time
combination and serve to give a negative Phosphatase Test that is applicable to milk immediately after
pasteurization only, and cooling it immediately to a temperature of 4°C or less.

Requirements

Stainless steel buckets, brushes for pipe cleaning, scrubbing brush, acid and alkali detergent (acid cannot be
a detergent), along with wetting agents and chlorine solution, double jacketed holder vat hooked up with a
surface cooler or plate cooler/multi purpose vat, milk filter, plunger etc.

Sterilization / Sanitization

1. See that the jacket is not containing chilled water. If so, divert it to the ice bank tank. Inject steam in
the previously cleaned tank of the batch pasteurizer till the temperature of the condensate reaches to
85°C. Slow down but continue the injection so that the temperature does not drop for 20 min.

OR-

2. Circulate the hot water at the same temperature for 20 min through all the pipes and pipe fittings as
well as through the vat.

-OR-

3. The chlorine water may also be used for cold (5-7oC) sterilization if required. In that case 200 ppm
chlorine solution may be used.

Operation

1. Take the milk in the pasteurizer by transferring it from balance tank through the raw milk pump.

2. Start the agitator for stirring the milk.

3. Fill well water in the jacket till there is overflow through the overflow pipe (well water pump is required
to be operated for pumping the well water).

4. Close the well water valve after switching off the well water pump.

35
 5. See that the circulation valve is open. Start the circulation pump.

6. Check that all the valves on the water pipe lines are closed. Open main steam valve and steam cock for
steam injection in the jacket.

7. Continue steam supply till desired temp. (63 °C) is obtained as indicated by the dial thermometer.

8. Hold at this temperature for the required time (30 min.). During holding period the agitator and
the circulating pump for spray pipe are kept on and steam injection is to be re-started only if the
temperature seems to drop below the set temperature.

9. Drain out the hot water from the jacket

a) Close the steam pipe line valves.

b) Open the well water valve and start the well water pump.

c) Let the water overflow and go to drain until the water going to drain is having about the same
temperature as that of well water. Preferably fill water in the jacket, circulate it for some time and
then drain it.

10. Close the well water valve. Open the chilled water inlet, and outlet valves and start the chilled water
pump. Continue this operation till the desired temperature (≤ 5°C) is obtained. Circulating pump can
also be started to improve rate of heat transfer.

11. Pasteurized and cooled milk can now be pumped for pouch filling.

Cleaning

1. Flush out the left over milk in the pasteurizer with ordinary warm water.

2. Disconnect the various pipe lines and put them in hot water tank.

3. Scrub the inner surface of the vat with the brush and detergent [sodium carbonate, Tri-sodium
phosphate (0.2 %), Teepol (0.1 %)] solution having 0.2-0.3% alkalinity.

4. Clean the pipe lines with pipe cleaning brush thoroughly.

5. Assemble them properly after sterilization. Keep the drain valve open to allow the vat to drain and dry.

Precautions

1. The counting of holding time is to be started when milk attains the desired temperature (63°C).

2. The upper cover of the batch pasteurizer should not be opened during operation to avoid post
pasteurization contamination.

3. The product should be agitated continuously during the progress of heating, holding and cooling to
achieve rapid heat transfer.

4. Care must be taken during cleaning so that all the surfaces have been attended to and positively made
free of milk residue.

Study Questions

1. Draw a sketch of Batch Pasteurizer plant.

36
 2. What precautions are to be taken while sterilization of the plant?

3. Describe the ' cleaning operation' of a batch pasteurizer.

4. What is the speed of agitator in a batch pasteurizer ?

OBSERVATION CHART FOR BATCH PASTEURIZATION

I. Particulars of equipment

1. Make:

2. Type:

3. Rated Capacity:

4. Speed of agitator:

II. Particulars of Raw Milk

1. Quantity :

2. Temperature:

3. Composition

Fat %:

SNF %:

Acidity:

4. C.O.B. Test:

III. Sanitization/Disinfection of the equipment and the pipe line circuit

1. Condition of Milk Contact Surface :

2. Method:

3. Temperature:

4. Duration :

IV. Processing

1. Time milk taken in the batch pasteurizer:

2. Temperature of well water in the jacket:

3. Heating of milk

Time started:

Time completed:

Total coming-up time:

37
4. Holding time at pasteurization temperature:

5. Cooling of the milk with well water from___°C to___°C

Time started:

Time ended:

Total time taken:

6. Cooling of milk with chilled water from____°C to___°C

Time started:

Time stopped:

Total time taken:

7. Total time for pasteurization of milk:

38
EXERCISE NO. 11 DATE: _________

TITLE: Operation of H.T.S.T. pasteurizer

Introduction

It is desired to have shelf life extension of fluid milk so that it can be distributed to the end user in reasonable
time and can be utilized within 2-3 days period. High Temperature Short Time pasteurization of milk (i.e.
minimum of 161.6 oF or 72 °C for minimum of 15 sec.) confers public health safety by destroying all the
pathogen, if at all expected to contaminate the milk. It also serves to kill most of the spoilage microbes at the
same time avoiding nutritive loss that is associated with boiling of milk. After pasteurization of milk the chilled
milk is packaged in suitable containers (i.e. polyethylene based pouches or plastic bottles) for its end use.

Objectives

1. To get familiar with the various parts of HTST pasteurizer.

2. To know about cleaning process for HTST plant.

3. To ensure safety of milk and to prolong the keeping quality of milk without any marked effect on its
flavour, nutritive value or physico-chemical properties.

Equipments and Materials

Pasteurizer, Milk pump, Pipe lines, Pipe fittings, Clarifier or filter, Temperature controller, Flow diversion valve,
Indication thermometer, Recording thermograph, Storage tanks, detergents and sanitizing agents, milk etc.

Procedure

Sterilization of plant

1. Before treating the milk, whole plant should be Sterilized by circulating hot (80-82oC) clean water for
30 min.

2. See that the valves on the pipes are so adjusted that the water from the outlet pipe of the plant is
returned to the vat, circulation tunnel or balance tank depending on the outlet.

3. Adjust the thermograph and the temperature in the dial contact thermometer for FDV and temperature
controller at 80-82°C and 84-85°C respectively.

4. Put the filter assembly in the filtration unit.

5. Take water in balance tank and start the milk pump. Let the water which is previously held in the plant
to drain out. Turn on the flow to the balance tank for circulation. Switch on cleaning, temperature
controller and automatic switches.

6. Start hot water pump, water heater, at the basement should be filled with water and steam valve on the
line should be opened.

7. Admit the steam to the heater after filling with water through the temperature controller unit.

8. Heat the circulating water until the thermometer on the outlet pipe of the plant shows a temperature
of 40-45°C at which temperature the nuts of the spindles should be loosened so that the plant starts to

39
 drip. This is done in order to protect the gasket and plates.

9. Continue the heating until the temperature of the water in the outlet pipe is about 80-85°C and circulate
at this temperature for 30 min for proper sterilization.

Pasteurization of milk

1. Start well water pump to cool the plant.

2. Drain out water through the storage tank and when there is least quantity of water in balance tank,
pour milk in the balance tank.

3. Start chilled water pump, switch off the cleaning switch and tighten the plates to prevent leakage. The
milk forces water out of the system. When the milk comes out of the plant, it is collected in cleaned and
sterilized can or may be diverted to cleaned and sanitized storage tank.

4. If temperature does not remain constant then adjust steam properly in the temperature controller
unit. Remove air present in the plant through air release valve provided on the filter.

5. When the last milk runs from the collecting vat to the milk pump, water is led to the vat. The water
forces the milk, out of the system.

6. When the water at the outlet pipe is free from milk, stop well water and chilled water pump and put
cleaning switch on, cut off the milk supply to storage tank and draining of water is to be started.

Cleaning of HTST pasteurizer

1. After completion of pasteurization of milk, when water comes out, stop milk pump and take away the
filter set.

2. Start again the milk pump after adjusting cover of the filter.

3. Flush the plant till there are almost no milk solids in the water. Remove milk traces from sampling cock,
air relief valve, circulating pipe and FDV line.

4. Circulate 50 lit of water and add 50 ml of 65% concentrated nitric acid per 1000 lit of milk treated. The
concentration may be kept in between 0.3 to 0.5 % acidity. Acid solution may be circulated in FDV line
for 20 min. and for the remaining time throughout the circuit.

5. Raise the temperature up to 65-70°C and circulate for 25 to 30 min.

6. Drain out the acidic water and remove all traces of acid from the plant by means of hot water.

7. Take again 50 l. of fresh water and circulate. Raise the temperature up to 80-85°C, add calculated
quantity of alkali chemicals (i.e., NaOH, Sodium hexa meta phosphate, Sodium metasilicate and Teepol
so as to attain strength of 0.7% alkalinity) (added before the temperature of water reaches 55°C)
circulate it for 25 to 30 min. (20-25 min in FDV line).

8. Drain out all the alkali solution and remove all traces of alkali from/the plant by means of well water.

9. Stop hot water pump and injection of steam in temperature controller. Circulate the fresh water and
start the well water pump to cool the plant.

10. Stop milk pump and well water pump, drain water from the balance tank.

40
 11. The steam supply to heater is closed completely, all the switches are put in off position and the arm of
the thermograph is lifted off the graph paper.

Study Questions

1. Give detailed flow diagram for operation of the HTST pasteurization of milk.

2. Briefly describe how hot water Generator is operated.

3. Draw a sketch of the control panel, filter assembly and locate flow inlet and outlet of the filter assembly
in a HTST plant.

4. Find out the holding capacity of the HTST plant.

5. If the plant has performed at less than its rated capacity, give reasons.

6. At what pressure is the hot water/chilled water circulated through the plant?

7. Give the necessity of servo pump/describe working of servo pump.

8. Is there any necessity of well water section when raw chilled milk is received at the plant? Why?

9. Why two set of pointers are provided in FDV?

10. Find out the operating capacity of the plant at full flow and at minimum flow.

11. Determine the volume (ml) of acid and lye used per liter of milk processed in HTST pasteurizer.

12. How can we assess the efficiency of cleaning and sterilization of HTST plant?

41
 OBSERVATION CHART FOR H.T.S.T. PASTEURIZER

I. Particulars of the HTST plant

1. Make:

2. Type:

3. Rated capacity:

II. Particulars of milk

1. Temperature:

2. Quantity:

3. C.O.B. Test:

4. %Acidity:

5. % Fat:

6. % SNF:

III. Sanitization/Sterilization of plant

1. Type of sanitizer and its strength:

2. Temperature:

3. Contact time:

IV. Pasteurization of milk

1. Time of starting pasteurization of milk:

2. Temperature of raw milk:

3. Temperature of milk after regeneration (after each Regeneration section):

4. Temperature of milk after final heating:

5. % Regeneration efficiency of heat obtained:

6. Temperature of milk upon cooling:

a) Well water cooling:

b) Chilled water cooling:

7. Total quantity of milk pasteurized:

8. Time (if any) of working of FDV:

9. Total time taken to pasteurize the given quantity of milk:

10. Actual capacity of the pasteurizer:

42
V. Particulars of pasteurized milk

1. Sensory quality of milk ________________________________________________________________________

2. Fat % ____________________, SNF % ________________________, Acidity LA % ________________________

3. Alkaline phosphatase test _____________________

4. MBR Time ________________________

5. Shelf life of milk at 50C______________________

VI. Cleaning

1. Rinsing/flushing time:

2. Acid cleaning

a) Type and Strength of acid used :

b) Temperature of acidulated water :

c) Duration of circulation

In FDV line:

In total circuit:

3. Temp of rinsing water:

Time of rinsing:

4. Alkali cleaning (Quantity of each alkaline detergent)

a) Caustic Soda:

b) Sodium Hexa Meta Phosphate :

c) Teepol:

d) Sodium meta silicate:

Quantity of alkali solution:

Temperature of solution:

Alkalinity (at the beginning):

Duration of circulation:

Alkalinity (at the end):

Alkalinity in FDV line:

Alkalinity in total circuit:

5. Temperature of rinsing water:

Duration of rinsing:

43
EXERCISE NO. 12 DATE: _________

TITLE: Operation of a plate Heat exchanger for cooling

Objectives

1. To get familiar with the operation of a plate chiller.

2. To chill the raw milk so that it keeps well till it is ready for heat processing

Equipment and Materials: Plate chiller, pipe line structure, milk pump, milk filters, balance tank,
detergents, filter, milk, cans etc.

Procedure

(a) Sanitization

Before handling milk, the whole plant surface likely to come in contact with milk is to be cleaned and sanitized
either by circulating hot water at 80-85 °C for 20-30 min. or by circulating 250 ppm available chlorine solution
for about 10 min. at 10-20°C. Generally the later is avoided, especially when chilling small quantity of milk.

1. Initially the pipe connections are tightened sufficiently to prevent leakage.

2. The pipe line and valves are connected/adjusted in such a way that water from the outlet pipe of the
plant is returned to the balance tank.

3. Fill the balance tank to about half level and start the milk pump. Flush the water out of the plant
initially.

4. Inject steam into water to raise its temperature to 85°C. The temperature at the outlet of the plant
should be at least 80°C.

5. The hot water is circulated for 25-30 min. The temperature should be maintained by injecting steam
as and when necessary.

6. Drain the hot water from the plant by adjusting the three way valve.

7. Open the well water and chilled water line valves and start the well water and chilled water pumps to
cool the plant.

(b) Chilling the milk

1. When the hot water is about to be emptied from balance tank, add milk to be chilled in the balance
tank.

2. The undiluted chilled milk starts flowing out, collect chilled milk in cleaned and sanitized cans. From
the time taken, for milk to travel from balance tank to the outlet of plant, find out the holding capacity
of the plant.

3. Adjust the temperature of milk by operating milk flow regulator provided at the outlet.

4. When milk is about to be finished in the balance tank, water is added and flushing action would
commence.

44
(c) Flushing

1. Prevent dilution of chilled milk.

2. The well water and chilled water pumps are stopped and their valves are closed.

3. Flush the plant till the outlet water is almost free from milk solids.

(d) Cleaning

1. Take about 40 l fresh water and add the following detergents after making its solution in plastic bucket
and filtering it through muslin cloth. Circulate the solution in the plant.

NaOH: 100 -150 g

Sodium hexa meta phosphate: 50-100 g

Sodium meta silicate: 50 -100 g

Teepol: 5 -10 ml

2. Inject steam to raise the temperature of detergent solution to 75-80°C.

3. Circulate the detergent solution for 15 -20 min.

4. Drain the alkali solution and flush the plant with water till it becomes free of alkali.

5. Cool the plant by circulating chilled water through the plant.

6. Acid cleaning prior to alkali cleaning is carried out occasionally depending upon the hardness of water
and scale layer deposition on the plates. The acid solution (0.5% HNO3) may be circulated at 60-70 °C
for 15-20 min.

Study Questions

1. Which sanitizer would you prefer out of chlorine and hot water for sanitization of a PHE plant? Why?

2. What is the operating capacity of the Plate Heat Exchanger?

3. What is the function of a flow regulating valve?

4. What is the holding capacity of the plant?

5. How does the three way valve function?

6. Which are the other techniques for cooling the milk, besides use of PHE?

OBSERVATION CHART FOR PLATE CHILLER

I. Particulars of equipment

1. Type:

2. Make:

3. Rated capacity:

4. Observed capacity:

45
 5. Chilled media used:

II. Particulars of milk

1. Quantity:

2. Temperature:

3. Acidity:

4. % Fat:

5. % SNF:

III. Operation of PHE

A. Sanitization

1. Type of sanitizer used:

2. Temperature of sanitizing solution:

3. Duration of sanitization:

B. Chilling of milk

1. Time chilling started:

2. Time chilling completed:

3. Total time taken:

4. Temperature of chilling media:

5. Temperature of chilled milk:

C. Cleaning of plant

1. Strength of acid :

2. Quantity of acid used:

3. Strength of acid solution:

4. Temperature of acid solution:

5. Duration of acid cleaning:

6. Duration of flushing the plant:

D. Detergent Cleaning

1. Detergents employed in alkali cleaning:

2. Active alkalinity of detergent solution:

3. Temperature of detergent solution:

46
 4. Duration of alkali cleaning:

5. Duration of flushing the plant:

6. Total duration of cleaning the plant:

Note: Acid cleaning is followed only infrequently, since milk stone deposition is not expected.

47
EXERCISE NO. 13 DATE: ___________

TITLE: Operation of a UHT Processing plant

INTRODUCTION

Ultra High Temperature (UHT) treatment is a modern method of sterilizing milk to obtain a shelf stable
product. The first UHT-treated and aseptically packaged products were in cans and were exhibited at an
agricultural exhibition in London in the mid 1920s. Long-life or UHT milk originated at Switzerland in 1961.
In the same year aseptic packaging procedures were introduced using flexible packaging material (laminate
of wax, paper and polyethylene) – the Tetra Pak system (Tetra Classic Aseptic). Food products including milk
are processed by UHT methods in order to obtain a commercially sterile product. Rapid heating, short holding
and rapid cooling minimize the occurrence of chemical change in processed milk. Milk to be subjected to
UHT treatment has to be homogenized to prevent cream plug formation in the package during its prolonged
storage. Such UHT milk has a long storage life (more than 3 months or even greater) and greater consumer
acceptability than the conventional canned sterilized milk; the latter suffers from greater alterations in
flavor, color and nutritional quality. UHT heated milk can be stored for a few months when stored at ambient
temperature (without cold storage).

In-container sterilization process in which milk is sterilized in either glass or High Density Polyethylene
(HDPE) bottles operate at lower temperatures (hence longer period) than UHT processes. The In-container
process requires a sterilization temperature of about 115-1210C for sufficient time (15-20 min) to ensure that
the product passes the ‘turbidity test’ used to determine the sterilizing efficiency of milk.

In case of Indirect UHT system, a heat exchange surface separates the product from the heating or cooling
media. The heating medium may be either steam or superheated water. Direct UHT plants feature direct
contact between the heating medium and the product. The heating medium is usually steam but electrical
heating (‘Elecster’, ‘Ohmic’) has also been introduced to a limited extent.

Extended shelf life (ESL) milk has a shelf life of about 3 weeks under chill chain conditions and fills the
gap between high-temperature short-time (HTST)-heated milk, which typically is assigned a shelf life of 2-10
days under refrigerated storage and UHT sterilized milk has a shelf life of more than 6 months at ambient
conditions. The thermal process requires direct or indirect heating at 123–127oC with a holding time of 1–5 s.
Traditional HTST pasteurization is carried out at 72–75oC for 15–30 s, and UHT milk is heated at a minimum
of 135oC for a few seconds (sterilization value F0 ³ 3 min).

Definition of UHT as per IDF: A UHT product produced by UHT treatment is packaged in a sterile container
under aseptic conditions. Typical temperature-time combination for UHT milk is 132°C for not less than 1 sec
(for UHT cream, the conditions are 132°C for not less than 2 sec.).

Advantages of UHT milk

ŠŠ UHT milk can be kept for several months without refrigeration, advantageous in warm summers.

ŠŠ UHT milk confers advantage when the distance between the producer and consumer is wide.

ŠŠ Temporary surpluses due to seasonal variations can be covered by subjecting milk to UHT treatment

ŠŠ Manpower costs are saved

ŠŠ Milk can be stored at home all the time; availability at odd hours and at distant locations.

48
Disadvantages

o Flavor of UHT milk is dissimilar to pasteurized milk.

o Nutritive value is marginally lower when compared to that of pasteurized milk.

o Higher cost of aseptic packaging

o Chances of formation of deposits within the system particularly in the direct steam system can incur extra
operating cost

o Proneness of UHT milk to age gelation during storage.

o Problems such as fat separation and sedimentation may occur during storage.

o The equipment and the process are expensive

OPERATION PROCEDURE

The Ultra High Temperature (UHT) milk sterilization plant installed at Department of Dairy processing and
Operations (Anubhav Dairy) is having installed capacity of 500 l/h (LPH). It is a skid mounted type UHT
Sterilizer plant. Aseptic filler is connected to fill the UHT milk into the pre-sterilized High Density Poly Ethylene
(HDPE) pouches. Set temperature for milk sterilization is 135°C and hot water temperature is set at 140°C. At
the outlet, milk is cooled at 25°C or 4°C by means of cooling tower water and chilled water respectively.

PLC operated Touch Screen control panel is provided for ease of operation. Operation sequence and procedure
is given below for the pilot scale plant.

OPERATION SEQUENCE

1. First fill the Hot Water tank with soft water 50 mm below the overflow pipe provided in the tank as
well as the product tank.

2. Connect the 440V power supply to the MCC panel (Figure 1).

3. Turn the key of control panel to “ON” mode. Select “ENGLISH” language mode by pressing the soft key
in the panel. “POWER ON” button should be pressed to operate the system through the panel

4. Then press the keys for Material Pump “ON”, Hot Water pump “ON” and product Auto Return “ON”.

5. By pressing function key we can operate ‘Temperature Control’ and ‘Parameters Control’.

6. Set the temperature of Hot Water to 140°C & milk pasteurization temp. at 135 °C.

7. Open ‘shut off’ to operate ‘Steam Control Valve’ and cooling tower water centrifugal pump.

8. Circulate the water to reach the temperature up to set point then flush out the water and push forward
the milk poured into the feed tank. Pump by pressing the keys on Control panel.

9. Meanwhile start the cooling tower supply pump and chilled water supply.

10. If temperature of outgoing product is less than 130°C and greater than 135°C (SET temperature was
135 °C), then the system will divert the flow of liquid back to the Feed tank.

11. UHT pasteurized milk will be packaged in pouches in filling machine at 25oC or at 4°C

49
 Fig. 1 Display panel on UHT plant for certain operations

UHT FILLING MACHING

Aseptic packaging is the final step in aseptic food processing ensuring that microorganism does not gain entry
into the package, which otherwise can cause either food spoilage and/or food poisoning. Aseptic packaging
ensures that the containers of the food (milk) are sterilized continuously and that the food is inserted into the
container in a completely sterile environment.

In order to maintain high quality in UHT processed products viz., flavourwise, microbiologically and
nutritionally, aseptic packaging becomes a necessity. ‘Aseptic’ in the context of the milk packaging industry
means the elimination of microbial recontamination of UHT processed milk to prolong its shelf life at ambient
temperature. In spite of all efforts, some defects may occur in the physical properties (gelation, fat separation,
sedimentation) of UHT milk.

Aseptic packaging involves

· Sterilization of packaging material

· Creation of a sterile environment while forming the container and/or filling the product

· Sealing of the containers thus preventing re-infection.

OPERATIONAL PROCEDURE

50
Capacity of the filling machine is 1000 pouches (250 ml and 500 ml capacity) per hour (PPH). It is connected
with UHT sterilizer plant. Aseptic filler is used to fill the UHT milk into the pre-sterilized plastic HDPE pouches.

Operation sequence for Aseptic filler

1. First carry out CIP of filling nozzle and pipe line.

2. Switch on the key of control panel. Press the soft key of “ENGLISH” language mode.

3. Fill the H2O2 (hydrogen peroxide – 20% solution) tank of 30 L capacity.

4. Push “DISINFECTION” button to start sterilization of front chamber. Set the “Disinfection” time at
minimum and maximum of 10 min and 30 min. respectively.

5. Then press “RUN” button. Once sequence completes, machine automatically ENTERs into OPERATION
mode.

6. In Operation mode, set the keys on “AUTO” mode and pull the RED point down. Now filling machine
will work in ‘Auto mode’ (set all parameters beforehand).

7. By pressing “SWITCH” button on touch screen we can choose any window to change the set parameters
(see Figure 2).

8. Choose window “PRODUCTION” to do ON/OFF for the following functions: “Vertical seal temperature”,
“Horizontal seal temperature”, etc.

9. First decide the volume to be packaged inside the pouch. Volume of milk has to be set by using manual
valve provided in PLC panel. Keep one precise weighing scale to check the weight of pouches filled
during the operation.

10. Open the window of “parameter setting” to set other parameters of vertical and horizontal heater
temperature.

11. Set the temperature of vertical and horizontal heater.

12. After that set “PULSE” and “POUCH LENGTH”

13. ‘Emergency stop’ has to operated and “GREEN” button pressed to start production.

51
52
53
EXERCISE NO. 14 DATE:__________

TITLE: Operation of a Homogenizer

Introduction

Whole milk, after heat treatment (pasteurization) when left at ambient or refrigerated temperature tends
to for a cream layer at top surface of milk kept in any container. Sterilized milk/UHT treated milk/sterilized
flavoured milk requires to be homogenized so that during its long storage (sterilized milk has extended shelf
life), the formation of ‘cream plug’ in bottles or ‘cream layer’ in other containers is not evident. Efficient
homogenization of milk leads to break down of the fat globules to a size < 2 μm. This helps in improving the
whiteness of milk, improves the viscosity (hence mouthfeel) and avoids fat separation in product.

Objectives

1. To study the mode of operation of a Homogenizer to homogenize milk/milk products

2. To study few factors affecting homogenization efficiency

Materials and chemicals

1. Milk

2. Plastic/SS vessels

3. Muslin cloth

4. Detergents

5. Concentrated nitric acid

6. Cleaned and sterilized milk cans

Procedure

(A) Assembling and sanitization

1. Assemble the pipe lines, filters etc. on the homogenizer.

2. Check and put on the water supply to lubricate and cool the homogenizer pistons.

3. Check the pressure control is in idling position (zero pressure).

4. Circulate water through the homogenizer by first taking water in hopper and then starting the motor.
Allow the air to escape through air vent valve. Allow some of the water in the beginning to flow out and
then start circulation.

5. Raise the temperature of this water to 80-85°C (preferably in can) and circulate the hot water through
all the parts of the homogenizer for 20 min. Take care not to direct steam towards the homogenizer
pump

(B) Homogenization

1. Meanwhile when sanitization is being continued, heat the milk to be homogenized to a temperature of
60°C and filter it.

54
 2. When all this is achieved, drain out the hot water and let the milk in the homogenizer first gradually and
then fully. At this time the direction of the outlet pipe should be towards the hopper so that whatever
milk passes through the homogenizer, is found circulating.

3. Now tighten the pressure control screw (second stage followed by first stage) in order to increase the
pressure which can be read on the pressure gauge. Increase the pressure up to 2500 psi (500 psi in
second stage and 2000 psi in first stage).

4. Turn the direction of the outlet pipe so that the milk comes out.

5. As the quantity of milk in the hopper reduces, add more and more milk to the hopper and homogenize
all the quantity of milk supplied. The homogenizer should never run in dry condition.

6. When finally a small quantity of milk remains in the hopper, turn the direction of the outlet pipe so that
milk circulates through the hopper.

7. Stop the homogenizer motor and drain the re-circulated homogenized milk from the hopper.

(C) Flushing and Cleaning

Cleaning of homogenizer should start as soon as homogenization process is completed.

1. First rinse the homogenizer with fresh water. Continue the rinsing of the plant till no milky water
comes through outlet pipe.

2. Circulate an alkaline solution (0.5% alkalinity) at 75-80°C temperature for 10 min. For this take 4 lit. of
water in the hopper and to this add after dissolving 20 g NaOH and 10 g sodium hexa meta phosphate
(SHMP). Preferably take water at 80-85°C, dissolve the required detergents. Filter it and then add this
to the hopper.

3. Rinse out the alkaline solution from the plant and see that no traces of the alkalinity are left in the
plant. Use preferably hot water (i.e. 70°C) for this purpose.

4. Removal of milk stones: If deposition of milk-stones occurs, the following method has to be used for
their removal.

a) Rinse with pure running water after homogenization is over till no milky water is coming out.

b) Then circulate for 15 min. a hot acid solution consisting of 20 ml 65% HNO3 in 4.0 lit. of water
at a temperature of 60-65°C. Then rinse again with pure running water till no traces of acid are
left in the water coming out through outlet.

c) Then circulate the above mentioned alkaline solution for required time at desired temperature.

d) Drain out the solution with hot water till no detergent traces remain in the circuit. Cool the
plant by circulating with well water/chilled water.

NOTE: Traces of acid or alkali are to be checked by litmus paper or phenolphthalein /methyl orange
indicator.

(D) Stopping the Homogenizer

After the cold water is circulated in the plant, stop the homogenizer motor. Close the valve that sprays
water on the piston for cooling and lubrication and drain the plant.

55
 Precautions to be exercised

1. The homogenizer should never be run dry.

2. During sterilization and cleaning of the homogenizer, the pressure should not be built up.

3. The milk to be homogenized should be strained with a muslin cloth before feeding it to the hopper.

4. Before starting the homogenizer motor make sure that the pistons are lubricated with water.

5. Dissolve all the cleaning agents first in a bucket or bowl and then strain the solution before allowing
it to be fed to the homogenizer.

Study Questions

1. Why milk is required to be heated at temperatures > 60°C before subjecting it to homogenization?

2. Write functions of each part of the homogenizer.

3. What modifications would you suggest to get efficiently homogenized product in following cases: (a)
Milk (< 8% fat), (b) Cream (40% fat) (Mention the operating parameters)

4. Describe the cleaning and sterilization operation homogenizer.

OBSERVATION CHART FOR HOMOGENIZER

A. Particulars of Homogenizer

1. Make and type of Homogenizer:

2. Stages in homogenizer (Singe/Two-stage):

3. Rated Capacity :

B. Particulars of milk

1. Type of milk:

2. % Fat:

3. % SNF

4. % Acidity:

5. Quantity :

C. Sanitization of Homogenizer

1. Temperature of hot water :

2. Time of circulation :

D. Operation of Homogenizer

Temperature of milk:

Actual pressure during homogenization:

56
 Observed actual capacity of Homogenizer:

E. Cleaning of Homogenizer

a) Acid cleaning

1. Acid used with its quantity:

2. Quantity of acid solution prepared:

3. Temperature of acid solution:

4. Time of circulation :

b) Alkali cleaning

1. Detergents used with their quantity:

2. Quantity of detergent solution prepared:

3. Active alkalinity of detergent solution:

4. Temperature of detergent solution:

5. Time of circulation:

F. Quality of Homogenized milk

1. Color

2. Flavour:

3. Viscosity:

4. Homogenization efficiency

a. Farrall Index

b. Creaming Index

57
EXERCISE NO. 15 DATE: ___________

TITLE: Preparation of Recombined milk

Introduction
Recombined milk can be prepared by blending a concentrated fat source (viz., Anhydrous milk fat [AMF]
or White butter) and concentrated SNF source (i.e. Skimmed milk powder) with water and subjecting it to
homogenization. This is often done in countries where there is insufficient milk production to meet the demand
for beverage milk consumption. Skim milk powder is dispersed in water and allowed to hydrate. AMF/white
butter is then emulsified into this mixture by either blending melted butter into the liquid mixture while hot,
or by dispersing solid butter into the liquid through a high shear blender device. The recombined milk product
is then pasteurized, homogenized and packaged as in regular milk production.
Definition as per FSSA: “Recombined milk or milk product” means a product resulting from the combination
of milk fat and milk-solids-non-fat in their preserved forms with or without the addition of potable water to
achieve similar end product characteristics and appropriate milk product composition as per the Standard for
that product and in the case of recombined milk, the source of milk-solids-non-fat shall be dried or concentrated
milks only. Such milk shall be pasteurized and show a negative phosphatase test. The water source must be of
excellent quality. The milk powder used for recombining must be of high quality and good flavour. Care must
be taken to ensure adequate blending of the ingredients to prevent aggregation or lumping of the powder.
Objectives
1. To prepare Recombined milk as per FSSA requirements
2. To prepare recombined milk to be blended with milk to cater to the demand of consumers in lean
season or to prepare recombined milk products
Requirement: Cream / white butter / AMF, SMP, plunger, milk can, high speed stirrer, muslin cloth, homogenizer,
potable water etc.
Procedure
1. Calculate the quantity of different raw materials required to achieve desired fat and SNF in the
recombined milk.
2. Warm the required quantity of potable water in a clean, sterilized can and slowly add SMP by sprinkling.
Continuous mixing with plunger or high speed stirrer is required. Allow the reconstituted milk to
hydrate for 1-2 hours.
3. Meanwhile melt the required quantity of white butter/AMF separately and mix with the contents of
can containing reconstituted skim milk.
4. Heat the recombined milk to at least 60°C.
5. Clean and sterilize the high speed stirrer, mix the contents for 2 min.
6. Homogenize the recombined milk at 2500 and 500 psi pressure.
7. Pasteurize the recombined milk by heating it at 75-80°C/15 sec. followed by cooling at about 4-5°C.
8. Analyze the milk for its fat as well as SNF content.
9. Assess the sensory quality of the fresh product.
10. Prepare blend of recombined milk with freshly pasteurized milk in proportions of 0:100, 25:75, 50:50,

58
 75:25 and 100:0 (v/v) and subject them to sensory evaluation.
11. Store the samples overnight in the refrigerator and again evaluate for its sensory quality.
OBSERVATION CHART FOR RECOMBINED MILK
1. Source of fat:
2. % fat and %SNF of fat source:
3. Source of SNF:
4. % Fat and % SNF of SNF source:
5. Quantity (kg) of:
a) Water:
b) Fat source:
c) SNF source:
6. Temperature of pre-heating:
7. Method of mixing:
8. Time provided for hydration of milk protein:
9. Particulars of milk homogenization
a) Temperature of milk:
b) Pressure:
10. Particulars of Recombined milk
a) Quantity:
b) %fat:
c) %SNF:
d) %Acidity:
11. Sensory Quality:
Prepare blend of recombined milk with fresh whole milk in several proportions (see Table 1). Pasteurize,
cool and proceed for sensory evaluation of the blended milk.
Table 1 Sensory profile of recombined milk blended with whole milk

Sensory attributes Sensory score of blended milk

(RCM : pasteurized milk, w/w)

0:100 25:75 50:50 75:25 100:0
Appearance (10)
Flavour (45)
Sediment (10)
Package (5)
Bacteria (25)
Temperature (5)
Total (100)
* Figures in parentheses indicates maximum score, RCM – Recombined milk

59
EXERCISE NO. 16A DATE: __________

TITLE: Preparation of flavoured milk/drinks

Objectives

1. To make milk more palatable so that more people, especially children can take advantage of nutritive
value of milk

2. To prepare value-added milk product

Materials

Fresh, good quality sweet milk, flavour essence, colouring matter, crystalline sugar, stabilizers, homogenizer,
pasteurizer, filter, plunger, milk can, bottles, etc.

Procedure

1. Ascertain the quantity of the product to be made and standardize the milk to required fat and SNF.

2. Weigh and measure the ingredients (dairy ingredients – whole milk, skim milk (for standardization),
skimmed milk powder; Non-dairy ingredients –sweeteners, flavouring, colouring) separately and keep
them ready for use.

3. Take standardized milk in a vat or vessel and raise its temperature to 65°C.

4. Homogenize this milk at a pressure 2500 and 500 psi in first and second stages respectively, after
proper cleaning and sterilization of the homogenizer.

5. Heat the homogenized milk to 80°C.

6. After the temperature is attained add the previously prepared sugar solution (~ 70oBrix) and heat this
mixture at 80°C for 10 min. (The sugar solution causes the dilution of milk. In order to compensate for
this, standardize the milk for a higher fat and SNF content). Instead of sugar syrup, crystalline sugar
may be added at the rate of 6-8 % by weight of milk.

7. Cool the product to < 5°C, add required quantity of desired essence (at the rate of approx. 1 ml/liter)
and colour (about 2 ml/liter), and mix thoroughly.

8. Fill this milk in clean and sterilized glass bottles. Place aluminum foil cap on the filled bottles. Store the
filled bottles under refrigerated condition

9. Record the flavour, colour and fat separation (if any) after 24 h.

Note: Use of stabilizers can help in improving the mouthfeel of flavoured milks. Sterilization of flavoured milk
may be carried out, especially when long storage is anticipated, without the need for refrigeration.

60
 OBSERVATION CHART FOR FLAVOURED MILK

1. Fat% and SNF % of whole milk

2. Quantity of skim milk (Fat_____,SNF_____) =

3. Quantity of standardized milk:

4. Fat and SNF % of standardized milk:

5. Addition of sugar: @ _________%, =__________ kg.

6. Homogenization pressure:

7. Homogenization temperature:

8. Homogenization efficiency:

9. Pasteurization temperature-time combination:

10. Total time taken for processing:

11. Temperature of flavoured mi1k after cooling:

12. Type of

a. Flavour used: _______ Quantity: __________

b. Colour used: ________ Quantity: __________

13. Filling capacity of bottle:

14. Volume of milk filled in package:

15. No. of bottles filled:

16. Sensory qua1ity of flavoured mi1k (Fill the score card given below)

Sensory Sample 1 Sample 2 Sample 3

parameters
Colour &
appearance (10)*
Flavour (45)
Sediment (10)
Bacteria (25)
Package (5)
Temperature (5)
Total (100)

*Figures in parentheses indicates maximum score for a given attribute

17. Shelf life of pasteurized flavoured milk: __________ at __ temperature (oC)

61
Study Questions

1. Which type of flavoured milks (using which flavours) are being produced commercially
in india?

2. What is the difference in the nutritive value of flavoured milk and normal cow milk?

3. What is the difference in the ‘shelf life’ and ‘cost’ of ‘flavoured milk’ and fluid milk’ of
similar composition?

62
EXERCISE NO. 16B DATE: __________

TITLE: Preparation of Sterilized Flavoured milk

Objectives

1. To prepare flavoured milk and subjecting it to sterilization to have prolonged shelf life at ambient
temperature of storage.

2. To study the difference in the shelf life of sterilized vs. pasteurized flavoured milk.

Equipments and materials

Whole milk, skim milk, sterilizable glass bottles, crown corks, sugar, colour, flavour, funnel, beakers, filter,
muslin cloth, plunger, Pre-heater, Homogenizer, Autoclave, sampling dipper, crown corking machine, milk
cans, etc.

Procedure

1. Reception of milk: Accept only good quality of raw milk. The quality of final product will depend on the
initial quality of raw milk. Judge the quality of milk by organoleptic, acidity, alcohol test and C.O.B. test.

2. Clarification/Filtration: Filter the milk using muslin cloth to remove extraneous matter, if present.

3. Standardization: Adjust the fat and SNF of raw milk to the desired level by the addition of skim milk/
cream or high fat milk, as the case may be. Keep desired safety margin in fat and SNF in view of dilution,
additives used etc.

4. Addition of sugar: Add sugar @ 6-7% by weight in the milk. This should be preferably done prior to
homogenization of milk.

5. Pre-heating: Heat the milk up to 60°C and filter it before homogenization. If milk is kept for longer
time before sterilization, provide pasteurization treatment to the mix.

6. Homogenization: Sterilize the homogenizer parts using hot water at not less than 85°C for 25-30
min. Homogenize the milk at a pressure of 2500 and 500 psi in first and second stage of a two-stage
homogenizer. Flushing and cleaning of homogenizer using appropriate detergents is to be carried out
after homogenization.

7. Addition of flavour and colour: Measure the required amount of flavour (about 1 ml/liter) and colour
(about 0.25 ml/liter) and add to the homogenized milk.

8. Preheating/Forewarming: Such treatment (85-95oC/10-15 min.) to milk is desirable and may include
use of stabilizing salts such as Na2HPO4 or trisodium phosphate at levels of 0.05-0.07% of milk.

9. Bottle filling and sealing: Fill cleaned and sterilized bottles manually or with the help of bottle filler.
The filling should be up to 90 % of the total capacity. Crown cork the filled bottles with the help of
crown cork sealing machine.

10. Sterilization

i. Put the crate of bottles in a rotary sterilizer or autoclave and close the door.

63
 ii. Keep the air release valve in open condition. Open the steam valve and let it come inside the
sterilizer slowly. Let the air present in the sterilizer be removed. The temperature of steam at the
out let should be about 100 °C. Close the steam release valve. Keep the by-pass valve provided
on the trap, in open position so that if any milk bottle breaks the steam trap side can be closed
to prevent clogging of steam trap. The pressure should be increased slowly to prevent thermal
shock to the bottle.

iii. Maintain the steam pressure at about 15 psi for 15 min.

iv. After 15 min period elapses, stop the steam supply. Allow the bottles to cool for 20 min.
Alternatively release steam slowly and attain zero pressure. Slowly open the door. The bottle
may be dipped in tub containing water at 90-95°C. Tap water may be added slowly to lower the
temperature of the bottles. But the temperature difference between the two should not exceed
25°C.

v. Remove random samples of sterilized flavoured milk bottles from crates to examine the colour,
fat separation and/or sedimentation (mainly in case of chocolate milk). The filled bottles can be
stored at ambient conditions and if the flavoured milk is to be served chilled, transfer the bottles
to cold room for about 2 h and then release the bottles for dispatch.

vi. Keep rest of the bottles for sale after necessary cooling.

Study Questions

1. Raw milk intended for preparation of sterilized flavoured milk shows negative C.O.B. test but positive
alcohol test. What would be your mode of action?

2. Draw a sketch of a batch sterilizer with complete labeling.

3. How can we prevent the breakage of the bottles in Sterilizer?

4. How do you know that all air has been removed from the sterilizer before developing steam pressure
in the plant?

5. What precautions should be taken during cooling of bottles?

6. How can we decide the quantity of flavour and colour to be added to milk?

7. Why headspace is required to be kept in the bottles while filling?

OBSERVATION CHART FOR FLAVOURED MILK

a) Fat % and SNF% of whole milk:

b) Fat% and SNF% of skim milk:

c) Quantity of standardized milk:

d) % Fat and % SNF of standardized milk:

e) Rate of addition of sugar:

f) Homogenization temperature and pressure(s):

g) Use of stabilizing salts, if any, Type _________________, Rate __________________

64
 h) Use of Stabilizers, if any, Type _________________, Rate __________________

i) Type and quantity of flavour used

j) Type and quantity of colourant used

k) Sterilization Pressure in Autoclave:

l) Corresponding temperature in Autoclave:

m) Time taken sterilization:

n) Filling capacity of bottle:

o) Volume filled in bottles/packs:

p) No. of bottles filled:

q) Details of sterilization:

Time crates loaded in the sterilizer:

Time steam supply started:

Time air vent stopped:

Time required to reach desired pressure:

Time of holding (at fixed temperature/steam pressure):

Time steam released and zero pressure reached:

Time of cooling bottles from _____°C to _____°C

Method of cooling the bottles:

Testing of Milk

Before sterilization:

Acidity:

C.O.B. test:

Alcohol test:

After sterilization:

Acidity:

Turbidity test:

Incubation test:

Note: In case of flavoured milk containing added colour, judging the end point of acidity is sometimes found
difficult

65
EXERCISE NO. 16C DATE: ___________

TITLE: Preparation of chocolate milk

Objectives

1. To study the preparation of Chocolate flavoured milk

2. To learn about the defects that may manifest in such flavoured milk

Equipments and materials : Whole milk, skim milk, skimmed milk powder, stabilizer (sodium alginate),
sugar, cocoa powder, homogenizer, plunger, muslin cloth, thermometer

Procedure

Standardization of milk

1. Determine the Fat% and SNF % of whole milk and skim milk.

2. Calculate the amount of both the milks required for obtaining the required fat and SNF in resultant
flavoured milk.

3. Mix the calculated amount of two milks thoroughly with cleaned and sterilized plunger.

Pre-heating

1. Take the standardized milk in a cleaned and sterilized can.

2. Put the can in the steam jacketed kettle and heat to 55-60 °C.

3. Continuous agitation should be done while heating the milk.

4. Meanwhile weigh separately the sugar @ 8-9 %, Cocoa powder @ 0.7-1.5% and stabilizer (e.g. sodium
alginate, CMC) @ 0.2% by weight of milk.

5. Mix half of the sugar with the cocoa powder and add to the hot milk by sprinkling followed by addition
of sodium alginate at 65°C, and then rest of the sugar.

6. Mix the content thoroughly and filter using muslin cloth.

7. Heat the milk to 60°C.

8. If the mix remains at high temperature for longer time before pasteurization, give pasteurization
treatment to the mix.

Homogenization of milk

1. Flush the homogenizer with tap water properly.

2. Sterilize it with hot water (80-85 °C) for a period of 20 min.

3. Homogenize the mi1k at 2500 and 500 psi pressure in first and second stage in a two-stage homogenizer.

Pasteurization of milk

1. Heat the homogenized milk at 85°C/no hold.

66
 2. Cool the chocolate milk prepared to ≤ 5°C

Bottle filling & storage

1. Take the required number of properly washed and sanitized (using chlorine solution 200 ppm) bottles.

2. Fill the bottles with the chocolate milk. Filling should be done up to the neck of the bottle, allowing
some head space.

3. Affix aluminum foil lid on the mouth of the filled bottles.

4. Put the bottles in the refrigerator (5 ± 2oC) for cooling.

Study Questions

1. Sugar syrup (60 % concentration) is to be used in place of sugar crystals. Find out its amount to be
added to prepare 100 kg chocolate milk. What modification/care needs to be exercised in standardizing
milk?

2. Describe different methods of preparing chocolate milk.

3. How can we reduce the incidence of settling of cocoa particles in stored chocolate milk bottles?

4. What can we do to improve flavour of chocolate milk?

5. How would you select bottles for flavoured milk which materials would be preferred for bottling of
flavoured milk?

6. Enlist the points from where contamination of the milk/mix may take place? What you would do to
prevent contamination?

7. What would be the expected keeping qua1ity of chocolate milk stored under refrigerated condition?

67
OBSERVATION CHART FOR CHOCOLATE MILK

1. Analysis of whole milk and skim milk

Fat %:

Acidity (%LA):

SNF %:

C.O.B. Test:

2. Pre-heating temperature:

3. Quantity of standardized milk :

4. Composition of standardized milk: %fat:_____,%SNF:____

5. Quantity of sugar and stabilizer used: _______, ______, ______

6. Homogenization temperature and pressure: _________, ____________

7. Pasteurization temperature-time combination:

8. Product cooled to temperature:

9. Type and quantity of flavouring (cocoa powder, chocolate liquor) used:

10. Number of bottles filled: __________

Sensory quality of chocolate milk

Sensory parameters Flavoured milk samples

Sample 1 Sample 2 Sample 3
Colour & appearance (10)*
Flavour (45)
Sediment (10)
Bacteria (25)
Package (5)
Temperature (5)
Total sensory score (100)

* The value indicated in parentheses indicates maximum score for that attribute

68