ANAND MILK UNION LIMITED

A Project Report on :

“Short term training”

@ Kaira District Co-operative Milk producers’ Union Ltd. , Anand .► Training Period : Starting From 22/12/08 to 2/01/09

► Shift Time : 12:30pm to 4:30pm

Prepaid By :

► Ronak Thakkar

► Jaymin Zala

3rd Year students of B.E.(FPT) , ADIT , New V.V.Nagar.

Anand Pattern

PRIMARY VILLAGE CO-OPERATIVE SOCIETIESMilk Production and Pooling through farmer producers

DISTRICT UNIONMilk Procurement & Manufauring of Dairy Products

&

Technical Inputs and Co-operative Development

Programmes to Farmers

STATE FEDERATIONMarketing

AI AH FEED EDUMILK

PRODUCTS

Money

Money

Introduction

For a milk farmer, whose life and livelihood is in our

rural hinterland, Amul is, Amul does!

This is the crux of the Amul brand and stems from the

support and ownership by over two million milk

producers of Gujarat

For the Consumer, Amul simply means 'Value For

Money' and Quality as it should be.

Amul makes each bite that much more special because in

our humble way, we care for feelings that are truly

"Indian".

HISTORY

In the year 1946 (14th December 1946) the first milk union was established. This union was started with 250 liters of milk per day. In the year 1955 AMUL was established. In the year 1946 the union was known as “KAIRA DISTRICT CO-OPERATIVE MILK PRODUCERS’ UNION”.

The brand name Amul means “AMULYA”.

Amul which inspired 'Operation Flood' and heralded the 'White Revolution' in India.

http://www.amul.com/. Is India's first national cyberstore, functioning in some 120 cities, and an Amul CyberstoreGifting Service capable of serving consumers in more than 220 of our cities, on specific occasions. This has been made possible by creating an IT network.

Amul-2 RMRD

This is very first department of any dairy where truck (cans) loaded with milk are unloaded and simultaneously the milk is tested and processed further in other departments. The RMRD at AMUL – 2 received cow milk and buffalo milk in separate cans.

Even today around 60% of mandadis (600) send milk to the amul dairy by cans each can have capacity of 65lit. Regular 33truks arrive here in morning. Milk is taken in B.T. & by pump it is forwarded to the pasteurizer.

▓▒Equipments :

1. Pasteurized milk storage tanke - 10 no. - 35729lits.

each - 16ft. deep

2. pasteurizer - 3 no.

Capacity – P1 = 17000 liters , P2 = 7500 liters ,P3 =

12000 liters

3. separator - 2no.s & speed 4600rpm

4.Butter milk tanks – 5no.s

5.Can Washer – 2no.s

6.Weighing balance tank Capacity – 500 kgs

& Collection tank Capacity – 2000 liters

7.Butter milk heating equipment (New arrived , IDMC)

Milk Pouch Packaging Here Packaging of milk ,buter milk ,dahi is done. In different

sizes 200ml,500ml & 1lit.(T-special).

* Made by : pre pac , pamar pan , set pac

Pouches are the most popular, convenient and accepted packaging for marketing of liquid milk. The Packaging Film Project (PFP) was established to give a competitive edge to the Co-operative Dairy, by ensuring access to the best quality food grade packaging pouch film, for high speed pouch filling machines, that operate at speeds 75 per cent higher than at present.

* Packaging Film Project, Gandhinagar.

U.V. light is used to protect pouches from bacteria.

speed selector is used for 200,500,1000ml pouches.

Horizontal & vertical sealing injection. – on/off

Impression coder is (of printech India) is used for marking Mfg. date & Batch no.

Valve control penal : from which we can select inlet tank(silo) & line. , for different products.

Flavor Section

☺Now a days amul is manufacturing of “14” types. 6

– in bottles & 8 –in tins. Namely : KOOL café , coco

, kesar , nutramul , rose , elaichi , Milk sek badam ,

banana , strabery , mango.

☺The plant have capacity to manufacture 1lac. Tins &

1lac. Bottles per day.

☺coming soon is whey milk in coco flavor. (in next 6

months). We are try to make this in R&D

laboratory(central lab) .

Process Flow chart

Sugar hopper

Sugar conveyor Slury tank

Provat

Homogenizer

Coffee blender

Bulk cooler

Packaging

Sterilizer

Cooling

Printing

Cartoon packaging

Amul – 3 Reception & process

“quality is prevention of wrong things”

► Purpose : To ensure that the process of milk reception ,

processing & issue or dispatch as per documented procedure.

Process Flow diagram

Source: Internet

Name of EQUIPMENT Capacity Number

Raw Milk Silo 1,50,000 Liters 4

Milk Clarifier 30,000 Liters 3 (Rpm – 1400 to 1500)

Raw Milk Buffer tank 15000 Liters 3

Milk Pasteurizer 30,000 Liters / hour 2 (PHE-type)

Cream Separator 30,000 Liters 2

Cream Ripening Silos 40,000 Liters 5

Cream Buffer Tank 40,000 Liters 3

Cream Pasteurizer 10,000 Liters per hour 1 (PHE-type)

Balance Tank 350 Liters 3

Pasteurized milk silo 1,50,000 Liters 2

Butter milk storage tanks 40,000 Liters 2

CIP tanks for tankers Water tank – 8000 Liter Capacity

Lye tank – 8000 Liters Capacity

1 each

CIP tanks Lye tanks Capacity – 10,000 Liters

Acid tank – 10,000 Liters

Water tank – 8,000 Liters

1 each

Sludge Process or Collection Tank 1 Cubic Meter 1

Sludge Stratification Tank 5000 Liters 1

Rinse tank 1

Rail tanker chiller Chilled upto 2ºC 1

Battery S.R.C valve & S.M.P valve

Butter►With the financial help from UNICEF, assistance from the

govt. of New Zealand under the Colombo plan, of Rs. 50 millions for factory to manufacture milk powder and butter was planned. Dr.Rajendra Prasad, the president of India laid the foundation on November 15, 1954. Shri Pandit Jawaharlal Nehru, the prime minister of India declared it open at Amul dairy on November 20, 1955.

►Largest plant in Asia. ( atli-butli delicious amul)

► They are paying Rs. 87/ton for AGMARK.

►Today , market share 85% Amul , 5% britaniya & 10% others.

► Here 100ton butter is prepared from 2lac lit. cream , everyday.

A

M

U

L

Process Flow diagram

Source: Internet

Ghee Section

Flow Diagram

PAST CURDED MILK CREAM

WHITE BUTTER ↓ ↓

CHURNING BUTTER

↓

WASHING

↓

MELTING VAT

↓

PRE-STARDIFICATION

↓ Ghee Residue

HEATING

↓

FILTERATION

↓

CLARIFICATION

↓

STORAGE TANK

↓

PACKING

Process for rework ghee

(A) process for pouch

• Separate the leakage pouch

• Cut by clipper & take ghee in separate can.

• filter ghee in can,

• Transfer into melting vat

• reprocess by heat

• empty pouch wash two time by hot water & take it into scrap

(B) process for tin

• separate leakage tin & re-work tin

• keep in tray for half an hour

• cut tin & take ghee in separate tank

• Transfer into melting vat & reprocess

• empty tin wash two time by hot water & take it into scrap

☺ Amul ghee is export in 14 countries

• Self life

• 15 months-

AUSTRALIA, U.S.A., KR OMAN,

CP BAHRAIN, QUATAR, HONG KONG,

BRUNEI, CHINA, SINGAPORE, T. KUWAIT.

• 12 months-

ABU DHABI, CP DUBAI, EGT

DHABI, CP DUBAI, EGT DUBAI, JAPAN

Laboratory

A. Amul-3 reception lab :

►Following are the test of raw milk ---

1. Determination of titrable acidity in raw milk

2. Clot on boiling test

3. Alcohol Test

4. Methylene blue reduction test (MBR test)

5. Fat Test

6. Determination of phosphate activity

B. Central lab• The dairy factory produces a variety of dairy products like

powder, butter, ghee etc. The various tests are carried out to check its quality.

• BUTTER

• Following are the tests carried out to check the quality of butter

1. Determination of moisture content in butter

2. Determination of salt content

3. Determination of SNF (curd) content in butter

• GHEE

• Following are the tests carried out to check the quality of the ghee.

1. Organoleptic grading test

2. Moisture content

3. Free fatty acid Test

4. Iron test

Refrigeration

• In refrigeration there are three diff. sections

1. -2 deg. C. system - Used for chilling the water

2. – 10 deg. C. system - Used for maintaining the temperature for ice silo.

3. – 30 deg. C. system - Used for cold storage and deep freezers

In amul lll 40% electricity consumed by refrigeration plant

Main parts of refrigeration sectios

1) Compressor

2) condenser

3) ammonia receiver

4) economizer

Boiler In AMUL Plant, there are total four boilers and all are fire

– tube type boiler.

The three boilers are having the capacity of 4 to 5 tonnes steam production per hour and the fourth boiler having the capacity of 10000 steam productions per hour.

The fuel gas that is used are off two types –1.Natural gas2.Furnace oil.

The water used for boiler should fulfill the following conditions –The pH is 8.5 to 9.5Hardness is 10 to 40 ppmChloride content is 400 to 800 ppm.

Substation

• Contract demand: 2800 KVA

Incoming Main power from two sub station :

1. Anand sub station

2. Mogar sub station

Main two part of dairy plant

1. Amul l & ll

2. Amul lll

For both plants separate sub station ,Anand & Mogar electricty available for both dairy plants

Amul l & ll Amul lll

Main 11 KV power supply comes in pole structure,

↓

Metering point.

↓

4 Nos. High tension (HT) breaker 4 Nos.

↓ 11KV

2 Nos. Transformer 2 Nos.

(1000 KVA) ↓ 440v (1500 KVA)

Low tension LT breaker

↓

Power control centre (PCC)

(MCCB OR Switch Fuse Unit (SFU))

↓

Motor control centre (MCC)

(MCB, Relay, Contactor)

↓

Motor (Machine)

ETP (Effluent Treatment Plant)

• 15 lac. Liters wastewater is treated per day.

Sr No. Parameter GPCB range Amul maintained

1 PH 6.5 to 8.5 7.5

2 COD 100 mg/l 80-90

3 BOD 30 mg/l 20-24

4 S.S. 100 mg/l 40-60

5 TDS 2100 mg/l 1100

6 OIL 10 mg/l 3-6

7 CL 650 mg/l 140-165