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Page 1: Banas Dairy An Oasis in the Desert

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Banas Dairy

An Oasis in the Desert

Banaskantha District Co-operative Milk Producers' Union Limited, Palanpur – 385 001

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Managing Director

Role of Dairy Sector

Inclusive growth in Banaskantha

Banas Dairy, Palanpur

Sanjay Karamchandani

Dr. Prahlad VaghelaManager (QMS)

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The dream of late Shri Galbabhai Patel,founder chairman and the selfless sage touplift Socio-economical status of villagefarmers came true after creation of aCooperative milk union forBanaskantha district, on the foot print of“Amul Dairy” of Kaira (Presently Anand)district, the model of a true co-operative

on (Anand Pattern) 10th March 1966.

Vision without action is merely a dream.

Action without vision passes the time.

Vision with action can change the world.

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Late Galbabhai Nanjibhai Patel, founder Chairman was a simple person with great foresightedness who had a dream

“To provide respectable life even to a widow residing in the farthest corner of villages with an aid of sickle, paving way to take up Animal Husbandry Activities and earn the wages

without injuring self pride ! ”

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COOPERATIVE

Cooperative is an autonomous association

of persons united voluntarily to meet their

common economic and social needs and

aspirations through a jointly-owned and

democratically-controlled enterprise.

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COOPERATIVE PRINCIPLES• Voluntary and Open Membership

• Democratic Member Control• Member Economic Participation• Autonomy and Independence• Education, Training & Information• Cooperation among Cooperatives• Concern for Community

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1969 LEADERSHIP 1991 to 2015

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Largest District by Population in Gujarat

Population Male Female

Ahmedabad 7,208,200 3,787,050 3,421,150

Surat 6,079,231 3,399,742 2,679,489

Vadodara 4,157,568 2,150,229 2,007,339

Rajkot 3,799,770 1,975,131 1,824,639

Banaskantha 3,116,045 1,609,148 1,506,897

Bhavnagar 2,877,961 1,490,465 1,387,496

Junagadh 2,742,291 1,404,506 1,337,785

Sabarkantha 2,427,346 1,244,491 1,182,855

Panchmahal 2,388,267 1,227,805 1,160,462

kheda 2,298,934 1,187,098 1,111,836

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Sr. No. Item Numbers % State %

1 Number of households 426,781 4.4 9,691,362 100

2 Population (Total) 31,16,045 5.16 6,03,83,628 100

2a. Males 16,09,148 51.81 3,14,82,282

2b. Females 15,06,897 49.19 2,89,01,346

3 Sex Ratio 940 918

4a Urban Population 4,13,337 13.26 2,57,11,349 42.58

4b Rural Population 27,02,708 86.73 3,46,72,279 57.42

5 SC Population 2,71,484 10.8 3,592,715 7.1

6 ST Population 2,05,904 8.2 7,481,160 14.8

7Decadal population

growth (1991-2001)24.43 19.17

8 Literacy (Total) 1,737,654 66.39 4,19,48,977 79.31

9a. Males 6,68,841 66.5 2,39,95,500 87.23

10b. Females 10,68,813 34.4 1,79,53,177 70.73

Source: census 2001

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Temperature between 50C to 450C

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Federal Structure of Co-operative

Operating

System

Members Non Members

Community

Governance Structure

Mic

roen

viro

nmen

t

Critic

al L

inkages

Operating

System

Members Non Members

Community

Governance Structure

Mic

roen

viro

nmen

t

Critic

al L

inkages

Operating

System

Members Non Members

Community

Governance Structure M

icro

envi

ronm

ent

Critic

al L

inkag

es

Village District State

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Dairy Industry

The majority of the world’s poor live in rural areas in countries.

They depend on agriculture production for income and food

security. Poor people should not have their income or food security

deriving from a single source; they need a number of safety nets or

livelihood diversifications.

At low risk and low cost, smallholder dairy production can be an

important economic activity. Dairying can reduce poverty and

improve livelihoods because of its high returns to land and labour,

and its many forward and backward linkages. The trade of milk

from rural areas to cities is an excellent tool for transferring capital

from richer cities to poorer rural areas.

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Dairy IndustryMilk (and Meat) has a high nutritional value and has a

significant impact on people’s nutrition, in particular for those

with special requirements such as children and patients.

Dairy development often increases the workload of women, but

it is also an opportunity for them to become more actively

involved in an economic activity and the process of change.

Furthermore Dairying generates a regular income for farming

communities and this encourages men and women to participate in

milk production activities. Smallholder dairy development is a

powerful tool for actively involving the poor in boosting rural

economic growth, initiating a process of change and improving

livelihoods.

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Dairy Industry Business for

Women Empowerment & Child Nutrition

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Regd. Cooperative Societies in the Revenue villages of Banaskantha

District

0

200

400

600

800

1000

1200

1400

10081037

10891119

1163 1178 1178

1251 1251 1255 12611290

2003-04

2004-05

2005-06

2006-07

2007-08

2008-09

2009-10

2010-11

2011-12

2012-13

2013-14

2014-15

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250.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15

1.872.01

2.28

2.60

2.983.08 3.12

3.18 3.22 3.26

3.43

Members' families (in Lacs)

0

50000

100000

150000

200000

250000

300000

350000

2010-11 2011-12 2012-13 2013-14 2014-15

Women

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MILK COLLECTION AND COOLING CASE STUDY CMP, ICD/VMS MILK PRODUCERS’ Awareness TRAINING

To cascade this quality initiatives further down to village level cooperative milk

producers’ societies a program called Vision Mission Strategy (VMS) was

introduced to all the villages and the milk producer members were trained in

scientific and clean milk production practices including feeding, breeding and

management of cattle.

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Initiatives for Farmers Internal Consultant Development Programme

Automatic Milk Collection Units : 100 %

Group Insurance for Milk Producers

Milk Yield Competition : To Identify & encourage

Manger and Chaff Cutter Scheme

Milk Day Celebration : Feedback mechanism

VMS Workshops : Planning

Clean Milk Programme : CMP

Member Pension Scheme : Swavlamban

Milking Machine & Animal Cooling System

Ration Balancing Programme : RBP

CDF / EDP : Entrepreneurship Development Programme

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Herd Improvement Projects

DIPA Project : Progeny Testing

Kankrej Conservation Project

Fertility Improvement Programme

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Frozen Semen Station : Dama

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Milk : Dairy Industry

Small holder milk production is characterized by the small

volume per producer, often of poor quality. A poor

infrastructure and transport system in an environment with a

high ambient temperature easily results in milk turning sour

before reaching a distant urban market or processing plant.

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MILK COLLECTION AND TRANSPORTATION Early Days at Banas Dairy, Palanpur

In 1969 in the absence

of road and village

level infrastructure our

collection system was

very primeval and the

milk which reach the

district dairy was either

sour or the acidity

would be so high that it

can not be used for

quality production.

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However, the collection of the milk was by milk cans in a

traditional fashion and the microbial quality remained

pathetic. Each village collected the small produce of agri-

farmer morning & evening and waited for the open trucks to

come and transport the milk cans to nearby chilling center.

BY the time the milk reach to the chilling center shelf life of

the milk (MBR time) would be reduced to less then half an

hour.

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Milk Transported in Milk Cans

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Transformation 1999-2015

Milk is a perishable product, which

easily get disturbed when not handled

with proper care.

India being the tropical country,

the environmental conditions

favour faster growth of

microorganism in milk and the

quality of milk gets deteriorated by

the time it reaches dairy dock.

Banaskantha is having Hilly area on eastern side & Desert of

Kutch at western side - Hot during Summer Season

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Transformation 1999-2015

Milk was coming in Cans, at every stage the

Quality gets deteriorated.

As per codex code on hygienic practice for

milk and milk products, milk should be

collected, transported and delivered

without undue delay, and in a manner

that avoids the introduction of Hazards

(physical, chemical and specially Biological)

into milk and minimizes the growth of

micro-organisms in the milk.

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Transformation 1999-2015

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Clean Milk Production

Installed Highest No. of BMCU at Village based Bulk Milk Coolers'

DCS Total 1083 : Procuring > 85% Milk as raw Chilled Milk - Procuring

more than Av. 1.5 million liters of milk as Raw chilled milk through Milk

tankers as input to most modern automated Banas – II & III Dairy Plants

4190 BMC in Gujarat

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Raw Chilled milk as Input to our Plants : Milk Tankers

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Banas Dairy Raw Milk Quality Initiatives : Industry Leader

0

200000

400000

600000

800000

1000000

1200000

Can Milk

BMC Milk

Year Can Milk BMC Milk Total (MT)No. of BMCU

1999-00 222218 0 222218 2

2000-01 208606 14990 223596 5

2001-02 223393 34297 257690 49

2002-03 237015 53225 290240 51

2003-04 208696 70966 279662 104

2004-05 261605 96677 358282 160

2005-06 274625 150814 425439 221

2006-07 242568 194458 437026 309

2007-08 259825 268629 528454 369

2008-09 258748 390724 649472 501

2009-10 211400 476956 688356 600

2010-11 187129 530534 717663 719

2011-12 159450 667287 826737 907

2012-13 193407 839804 1033211 910

2013-14 203902 889672 1093574 1004

2014-15 175775 1008131 1183906 1083

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This is why we exist.....

C to CCow to Customer

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Tribal Dairy Coop. Society

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43Dairy Coop. Society

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2015 : Now Milk is being collected through Automated milk collection

system & get chilled at BMC 40C

1400 Village level Dairy Cooperative

Societies already have AMCS

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T.Q.M. Total Quality Management Since 1999Customer & Quality Focus : Supply Chain

• 5S : Housekeeping 1999

• Kaizen 1999

• Q C Circles 2000

• SGA : Small Group Activities

• TPM

• Cleaner Production : CP 2006

• SIX Sigma 2007

• SAP 2011

• ISO 9001:2008 & ISO 22000:2005

• ISO 9001:2008 at Village DCS

• Training : In-house & External

• HOSHIN KANRI

• 3 times since 1999

• 1999 – 2007 : HK

• 2005 – 2010 : CP

• 2010 – 2015 Manthan

• 2015-2020 : Mission2020

• Functional KPIs

• Banaszen Reports

•• WCM

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Dairy Animals & Milk Producers

Village Dairy Coop. Societies

Customer

Banas Dairy

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Progressive Dairy Farmers

Training

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Progressive Farmers Farm Visit

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PDF PMP In-house Training

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PDF PMP In-house Training

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PDF PMP In-house Training

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PDF PMP In-house Training

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PDF PMP In-house Training

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PDF PMP In-house Training

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PDF PMP In-house Training

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BenchmarkingTour : Dairy Farm

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Benchmarking Tour

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Benchmarking Tour

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2014 -15

Batch No. No. Of Participants Days

25 1835 6

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PDF PMP In-house Training

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Progressive Farmers Farm

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Progressive Farmers Farm

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Progressive Farmers Farm

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Progressive Farmers Farm

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ISO BMCU DCS MRM Oct 2014

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ISO BMCU DCS MRM Oct 2014

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ISO BMCU DCS MRM Oct 2014

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ISO Audit Closing Meet

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ISO Audit Closing Meet

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71Forward together! 71

TOTAL QUALITY MANAGEMENT

TQM - Management approach of an

organization centered on Quality

Based on participation of all its

members and aimed at long term

success through customer satisfaction

for ultimate benefits to the members

as well as Society at large.

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Total Quality Management Principles

1) Customer Focus.

2) Leadership.

3) Involvement of People.

4) Process Approach.

5) System Approach to the Management.

6) Continual Improvement.

7) Factual Approach on Decision Making.

8) Mutual beneficial Supplier Relationship.

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KAIZEN MIS 2012, 2013 & 2014

0

200

400

600

800

1000

1200

1400

1600

1 2 3 4 5 6 7 8 9 10 11 12

2012 2013 2014

954 1095 1061

833 1249 982

999 1012 1028

942 980 998

1065 910 1058

1140 829 961

964 1467 1240

946 1415 1055

1068 1117 840

869 885 983

1068 863 1181

1060 1069 1349

11908 12891 12736

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KAIZEN MIS Since 1999YEAR KAIZEN YEAR KAIZEN

1998 5158 2006 4352

1999 19098 2007 5712

2000 6584 2008 4796

2001 1620 2009 6356

2002 4598 2010 9121

2003 3923 2011 9859

2004 5663 2012 11908

2005 5437 2013 12891

2014 12736

Oct. 2015 11223

Total 140920

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Red Tag Day : 1st SAt Dairy Campus JanuaryAt All DCS on 2nd October

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Red Tag Day at VDCS on 2nd October Every year on Gandhiji Birthday

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5S : Housekeeping at Banas• Whole Banas Dairy is divided in various HK

Zones & HK Categories.

• Each HK Zone having HK Coordinators.

• Monthly HK Coordinators Review Meeting.

• Initially Bi-monthly & afterwards Quarterly HK

Audit since Aug. 1998.

• Till Date 64 HK Audits conducted with 3 times

revised HK Checklist.

• 5 times no. 1 winner HK Zones becomes HK

Champion appreciated with HK Trophy & Gifts

to all Employees.

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Motivational Programmes

• Kaun Banega No. 1 : HK Quiz Contest : 2000

• Housekeeping Week Celebration : Awareness : Management by Walking / Talking around.

• Housekeeping Debate Competition : 2003

• Housekeeping Slogan Competition.

• Housekeeping Essay Competition.

• General 5S : Housekeeping Awareness trg.

• HK Internal Auditors training : Refresher also.

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HK Coordinators’ Out of Campus Meet

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Benchmarking Other IdealAMUL DAIRY VISIT

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Benchmarking Other IdealAMUL DAIRY VISIT

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Benchmarking Other IdealMOTHER DAIRY VISIT

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Benchmarking Other IdealBIRLA CELLULOSIC PLANT VISIT

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Benchmarking Other IdealBrahmakumaris Campus Visit

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Benchmarking Other IdealAdani Port, Adani Wilmar Oil

Mundra

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89

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House Keeping Roadmap of Year 2015

ACTIVITY Jan Feb

⦁ ⦁ ⦁ ⦁July

Augus

t

⦁Oct Nov Dec

⦁ Compulsory⦁ MONTHLY REVIEW

Agenda :Review of previous

meeting HK Audit / Result

Declaration Problems / MIS +

Sharing of good things by

coordinators

HK Roadmap Review

HK Coordinators Presentation

*&

*&

*&

*&

*

&

*&

*&

*&

*&

*&

*&

*&

HOUSEKEEPING AUDIT K K K K

RED TAG WEEK celebration $

HK Day : Every 15th of the Month.

By suitable means...s s s s s s s s s s s s

Surprise Hygiene Visit by Special

Team †† ††

PROMOTIONAL Activities

Housekeeping Week Celebration

Housekeeping Awareness

ActivityK K K K

Special Outside HK Meeting

Vyashan Mukti Movement s

In house training for H.K.

Coordinator & Auditors

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Comparision of 63rd and 64th H.K. Audit Results among the following SectionsZone Audit Marks Zone Audit marks

NO 1 Chilling Centres 63rd 64th No 4 Banas-II hygiene 63rd 64th

KCC 76 77 LMP-2 80 82

TCC 78 77 Butter-2 81 80

DCC 71 72 60 TPD 74 79

DAMA 74 69 UHT 76 82

RDCC 80 78

No2 Office Categry 63rd 64th No 5 Service Category 63rd 64th

Ground Floor 67 68 Engg Section 80 67

First Floor 72 74 Utility Section 81 72

Canteen 60 63 CFP 74 69

GDCTC 72 72 Main Stores 76 67

Garden 73 72 FP Stores 72 65

DH 65 65

No 3 Banas1 Hygiene 63rd 64th No 6 LMP-3 63rd 64th

LMP-1 68 77 Butter-3 80 78

Ghee, Paneer and Cheese 76 73 Icecream 84 85

QA Laboratory 72 68 QA Both 2&3 77 79

20 TPD 70 68 LMP III 80 79

30 TPD 68 69 100 TPD 62

Average 74 73

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Housekeeping Appreciation : Agri. & Garden

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Housekeeping Appreciation : QA Lab.

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Housekeeping Appreciation : LMP II

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Housekeeping Appreciation : Cattle feed Plant

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Housekeeping Appreciation : Engineering

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Housekeeping Appreciation : Agri. & Garden

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Housekeeping Appreciation : TharadCC

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Housekeeping Appreciation : Dama Semen Prod. Unit

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Housekeeping Appreciation : TharadCC

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5 times : HK Champion ZonesSr.No. Zone Section Name Audit No. Remark

1 chilling centre DANTA C.C. 2 TO 6 5 TIMES

2 office categary VET & DH 1 TO 5 5 TIMES

3 office categary MAIN OFFICE -GROUND FLOOR 8 TO 15 8 TIMES

4 Banas-I hygiene LMP-I 11 TO 17 7 TIMES

5 chilling centre DHANERA C.C. 16 TO 20 5 TIMES

6 office categary GARDEN AND ROAD 20 TO 25 6 TIMES

7 Banas-II hygiene UTILITY 20 TO 24 5 TIMES

8 Banas-I hygiene 20 TPD 27 TO 31 5 TIMES

9 office categary GARDEN AND ROAD 28 TO 37 10 TIMES

10 service categary WORK SHOP ENGG B-I 25 TO 31 7 TIMES

11 Banas-II hygiene BUTTER (B-II) 26 TO 35 10 TIMES

12 Banas-I hygiene QA LAB B-I 33 TO 37 5 TIMES

13 chilling centre KHIMANA C.C. 35 TO 39 5 TIMES

14 Banas-II hygiene LMP-II 36 TO 40 5 TIMES

15 service categary WORK SHOP ENGG B-I 37 TO 41 5 TIMES

16 chilling centre RADHANPUR C.C. 39 TO 43 5 TIMES

17 office categary GARDEN AND ROAD 40 TO 44 5 TIMES

18 Banas-II hygiene QA LAB B-II & UHT 43 TO 47 5 TIMES

19 Banas-I hygiene QA LAB B-I 45 TO 49 5 TIMES

20 service categary CATTLE FEED PLANT 46 TO 51 6 TIMES

21 chilling centre THARAD C.C. 46 TO 61 16 TIMES

22 office categary GARDEN AND ROAD 49 TO 53 5 TIMES

23 Banas-II hygiene LMP-II 50 TO 54 5 TIMES

24 office categary Main OFFICE -1 FLOOR 56 TO 60 5 TIMES

25 Banas-II hygiene UTILITY ( B-II ) 51 TO 60 10 TIMES

26 Banas-II hygiene LMP-III 56 TO 61 6 TIMES27 Banas-II hygiene BUTTER (B-II) 58 TO 62 5 TIMES

28 Banas-I hygiene GHEE -PANNER-CHEESE-AMULKOOL 59 TO 63 5 TIMES

29 Banas-I hygiene CATTLE FEED -KATRAVA 59 TO 63 5 TIMES

30 Banas-III hygiene ICE CREAM -BANAS-III 61 TO 65 5 TIMES

31 service categary UTILITY ( B-II ) 63 TO 67 5 TIMES

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102TQM-HRD CELL

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BANAS DAIRY EXHIBITION STALLAMBAJI – SADBHAVNA

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BANAS DAIRY EXHIBITION STALL DEODAR KRISHI

MAHOTSAV

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BANAS DAIRY EXHIBITION STALL DEODAR KRISHI MAHOTSAV

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LABOUR CONTRACTORS’ FSMS Awareness

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LABOUR CONTRACTORS’ FSMS Awareness

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LABOUR CONTRACTORS’ FSMS Awareness

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PRODUCTION EMPLOYEES FSMS Awareness

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PRODUCTION EMPLOYEES FSMS Awareness

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PRODUCTION EMPLOYEES FSMS Awareness

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PRODUCTION EMPLOYEES FSMS Awareness

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QCC – Quality Control Circles

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Fire Safety

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Self Managing Leadership

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Causing Incredible Performance

12/8/2015 124

Prof C Balaji

Founder, Partners in CIP

Email: [email protected]

Mobile: +91 9980 102 087

Skype: prof.balaji

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What Incredible Performance Is :Getting a Feel

125UNDERSTANDING CAUSING INCREDIBLE PERFORMANCE

CurrentPerformance

Business-As-Usual

Performance

Stretch Performance

Impossible Performance

PastPerformance

Incredible Performance will be somewhere in

this range

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Causing Incredible Performance

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Causing Incredible Performance

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Hoshin Kanri : Manthan 2015

Organization Purpose

Customers & their Expectations

S.W.O.T. Analysis

VISION

MISSION

STA : 60 identified

SMART Goals

Action Plan

Review

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Hoshin Kanri : Manthan 2015

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Milk Producers : MISSION 2020

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Customer Req., Organization

SWOT

VISION

MISSION

STAs

SMART GOALs

ACTION PLAN

TEAM & REVIEW

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MISSION 2020

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Glimpse of Banas Dairy

Total DCS - 1185 - 1290Total Members - 1,47,808 - 3,42,517Av. Milk Procurement - 6.13 LLPD - 32.44 LLPDPeak Milk Procurement - 8.11 LLPD - 41.70 LLPDSales Turnover Rs. - 355.49 Cr. - 5441.73 Cr.

2000-01 2014-15

Year Av. Milk Peak Milk

2000-01 612569 810829

2001-02 705682 986184

2002-03 794977 1086722

2003-04 765727 1023007

2004-05 981481 1409745

2005-06 1165494 1635937

2006-07 1196657 1664855

2007-08 1443424 2106278

2008-09 1779375 2430340

2009-10 1885907 2499935

2010-11 1966200 2502064

2011-12 2265033 3007266

2012-13 2736266 3545806

2013-14 2996093 3505355

2014-15 3243575 4170620

0

500000

1000000

1500000

2000000

2500000

3000000

3500000

4000000

4500000

Av. Milk

Peak Milk

On 23.11.2015 Milk Receipt 44,34,639 Kg Milk

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AMUL PATTERN

Village based Primary

Dairy Co-operative

Societies : 1,409

District Place :

Banaskantha District

Co-op. Milk Union Ltd.

District Level : Banas

Processing Plant

BANAS DAIRY 2014-15

Av. Milk 32.44 LKgPD

Milk Producers

members : 3.43 Lakhs

Village based Primary

Dairy Co-operative

Societies : 18536

Network : District Co-

op. Milk Unions :

16+1=17

State Level : Marketing

Federation, GCMMF

State Federation GCMMF 2014-15

Av. Milk 152.90 LKgPD

Milk Producers

members : 3.365 Million

4.17 Million Peak

Milk Receipt

22

%

10.19

%

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135Tharad Milk Chilling Centre

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Tharad Milk Chilling Centre

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Banas I Dairy Plant - Year 1969

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Banas - II Dairy Plant - year 2000

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Banas - II Dairy Plant

Banas - II Dairy Plant

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Banas - III Dairy Plant – year 2010

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Banas Dairy – TETRAPAK : UHT Plant

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Balanced Cattle Feed Plant 1000 MT – Year 2012

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100 TPD Powder Plant2015

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Banas Dairy Campus

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Banas Dairy Campus

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ISO 9001 : 1994 QMS & HACCP

ISO 9001 and HACCP

We are the First Dairy Co-

operative certified by BIS -

Bureau of Indian

Standards as per IS/ISO

9001:1994 integrated with

HACCP since July 1999.

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ISO 9001:2008 : QMS

certification of our

910 Village based Dairy

Cooperative Societies

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We plan to have 100 % milk procurementthrough farm cooled system and we shall be5 million litres per day milk dairy havingturnover of 50 billion INR organization by year2016.

We have also recently introduced FSMS FoodSafety Management System to meet theconsumer delight and human safety.

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ISO 22000:2005 FSMS

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Quality Assurance Commitment

BACTOSCAN FC 50 with Accessories……worth Rs. 66 Lakhs

FOSSOMATIC MINOR ……… worth Rs. 26.25 Lakhs

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Financial Benefit

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Financial BenefitMilk is the largest agriculture commodity in the country with its

revenues expected to be around Rs. 4 lakh crores in value terms.

Further, milk today touches the lives of millions of rural milk

producers, especially women engaged primarily in this vocation.

It is important to note that milk and milk products forms the

largest share of expenditure on food item in a consumer basket.

During the year, sales of our Federation registered a quantum

growth of 14% to reach Rs. 20733 crores ( 181 billion). Last year,

our turnover was Rs. 18143 crores (Rs. 181.43 billion). ……..

Where as Banas Dairy sales Turn Over was Rs. 5441.73 crores.

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Financial Benefit

INFRASTRUCTURE at

Villages : BMCU & DCS Buildings

No.

BMCU

Capacity Unit Price

No. of BMCU

installed Total Cost

1 1000 Lit. 368000 64 23552000

2 2000 Lit. 525000 393 206325000

3 3000 Lit. 753000 95 71535000

4 5000 Lit. 913500 337 307849500

5 10000 Lit. 1725000 49 84525000

TOTOL 1083 1063786500

DCS having own Building

Building by own investment Building by Loan

1000 661 339

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Normally producer’s shares in different commodity groups in India are as follows:

• Food grains - 55 to 65%• Milk - 80 to 86%

• Fruits - 30 to 40%

• Vegetables - 40 to 50%

We have ensured that Indian dairy Farmers get maximum share of Consumer’s Rupee spent on Milk & Milk Products

Source : www.indiaagronet.com

Supply Chain Efficiency

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India

• Indian dairy cooperatives ensure that their farmers get 80% - 86% of Consumers Rupee spent on Milk & Milk Products

Other Countries

• In USA, producers get 38 % of consumers’ money spent on milk.

• In UK, producers get only 36 %.

Just Contrast this with some of the

other countries…….

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Price paid (Rs. / Kg. fat)

0

100

200

300

400

500

600

700

179 177 180

210224 219

255

295 302

360

427

500 505

590

682

Price Paid Rs. / Kg Fat

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Sales Turn Over - Banas Dairy – Banaskantha Dist., Gujarat

0

1000

2000

3000

4000

5000

6000

2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15

547 597768

934

1150

1547

1926

2265

2916

3549

4687

5442

Sales Turn Over (Rs. In Crores)

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Since the Dairy Husbandry in INDIA is mostly looked after bywomen, the economic empowerment of the women has beenstrengthened and it gave more disposable income to the womenfor spending on Health, Nutrition and Education of their Children.This has brought Socio-economic revolution in the area,improving the Quality of Life of Rural milk producers.

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BANAS DAIRY

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

45.00

સરેરાશ દૂધ સપંાદન (લાખ કિલો)CAGR 9 % Overall

16 % last decade

Year 2014-15

Av. 32.44 LLPD

Peak 41.70 LLPD

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8. Impact on Environment & Society Sustainable Ecological Development - 'Green Amul Green India' Campaign

• 16.38 Lakhs 15.08.2010• 15.26 Lakhs 15.08.2011• 16.25 Lakhs 15.08.2012

Blood Donations Camps 26:580 bottles

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HEART CAMPS4 times

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Organization with Difference

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Organization with DifferenceEnergy Dense Extruded /Roasted Fortified Blended Food –THR : Take Home Ration the Aganwadi Centre’s Beneficiaries :

1. Bal bhog2. Sukhadi Premix 3. Sheera Premix4. Upma Premix

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Organization with Difference

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Customer & Quality Focus

Offering the

entire range

of Amul

Products

under one

roof

Coming Closer to Consumer

The Taste of INDIA

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Customer & Quality Focus

Coming Closer to Consumer

Offering the entire range of Amul Products under one roof

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Customer & Quality Focus

Offering the entire range of Amul Products under one roof

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Product Portfolio based on Life-cycle segmentation……..

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Top Milk Processors of World

IFCN Top 20 Milk Processor list 2014

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& our farmers became …..

…recipient of most prestigious awards in various fields

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Recognition : Productivity AwardsTotal 11 - National Productivity Council Awards in

Productivity Performance - Dairy Processing

Banaskantha District

Cooperative Milk Producers’ Union Ltd.,Palanpur

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Banaskantha District Cooperative

Milk Producers’ Union Ltd., Palanpur

RAJIV GANDHI NATIONAL QUALITY AWARD 2008

WINNER (COMM. CERTIFICATE) DRUG & FOOD

SECTOR…….. Large Scale Manufacturing

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Recognition : QCI AwardQUALITY COUNCIL OF INDIA : DL SHAH AWARD

WINNER (ECONOMICS ON QUALITY)

On 11.2.2011 at NEW DELHI

Banaskantha District

Cooperative Milk Producers’ Union Ltd.,Palanpur

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Banaskantha District Cooperative

Milk Producers’ Union Ltd., Palanpur

RAJIV GANDHI NATIONAL QUALITY AWARD 2011

WINNER (COMM. CERTIFICATE) DRUG & FOOD

SECTOR…….. Large Scale Manufacturing

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Recognition : QCFI Awards 5S : Gold Award 2012 QCC Gold Award 2013

Banaskantha District

Cooperative Milk Producers’ Union Ltd.,Palanpur

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Recognition : QCFI Awards 2014

CFPlant 5S : Gold Award QCC Gold Award

Banaskantha District

Cooperative Milk Producers’ Union Ltd.,Palanpur

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Banaskantha District Cooperative

Milk Producers’ Union Ltd., Palanpur

ICE DENFOSS AWARD 2014 WINNER

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Banaskantha District Cooperative

Milk Producers’ Union Ltd., Palanpur

CII NATIONAL FOOD SAFETY AWARD 2014 WINNER

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CII NATIONAL FOOD SAFETY AWARD 2014 WINNER

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Banaskantha District Cooperative

Milk Producers’ Union Ltd., Palanpur

CII NATIONAL FOOD SAFETY AWARD 2014 WINNER

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Recognition : QCFI Awards 2015

TharadCC 5S : Gold Award QCC Silver Award

Banaskantha District

Cooperative Milk Producers’ Union Ltd.,Palanpur

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The difference between ordinary and extraordinary is a little

EXTRA

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We follow principles of Quality Management

• Customer Focus

• Leadership

• Involvement of People

• Process Approach

• System approach to management

• Continual Improvement

• Factual approach to decision making

• Mutually beneficial supplier relationship

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“We have traversed a path that few have dared to.

We are continuing on a path that still fewer have the courage to follow.

We must pursue a path that even fewer can dream to pursue.

Yet, we must, we hold in trust the aims and aspirations of millions of our countrymen.”

- Dr V. Kurien1921-2012

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