INTERNSHIP REPORT

TO:
Mam Dr. Maria Mustafa
BY:
Mubashar khurshid

sp12-bec-031

Department of Chemical Engineering

COMSATS Institute of Information Technology,Lahore

Contents
SUMMARY..........................................................................................................................................
Acknowledgement.................................................................................................................................
History..................................................................................................................................................
PRODUCTS..........................................................................................................................................
Reception lab.........................................................................................................................................
PROCESS LAB.....................................................................................................................................
PASTEURIZATION...............................................................................................................................
Powdered Milk Plant............................................................................................................................
Boiler section.......................................................................................................................................
CIP.................14

SUMMARY
Premiere Dairies is an organization working in Pakistan. It has a good control system and culture .Its
current markets are mainly the hilly area which include K.P.K and Sindh with only specific products
targeting some areas of Punjab and Balochistan.It has many products ,but the main is U.H.T Milk.
Nowadays, its lean season and the production of U.H.T Milk is low as compared to flush season.

Acknowledgement
In the name of ALLAH who created this universe and left it for men to explore the new horizons and
to be concurred. He has bestowed his masterpieceMAN with the greatest strength in the universe
that is knowledge. With the help of this knowledge man going higher and higher and is seeking for
new destinations. This knowledge that make things easier and easier to be done. Same is the case
with us, we with the help of this knowledge have been able to do such a job regarding to our final
internship report of PREMIER DAIRIES if ALLAH had not given us the power of knowledge,
skills and commitment to do we could not be able to accomplish this task. Then we would like to
remember our last messenger Hazrat Muhammad (PBUH) who is the person through whom
knowledge came to us and who enlightened the world with his message and brought the human being
out of darkness of ignorance to the light of knowledge. I would like to thank my parents who always
encourage us at the time when we became disappointed and it is the reality without their untiring
efforts I could never do this. At the end we would like to thank my Department and teachers who
provide me an opportunity to practice my learning in form of internship. We pray our gratitude from
the core of my heart to management and of PREMIER DAIRIES as without their help and
guideline; we could never been able to complete this task .

History
Premier Dairies was incorporated in 1999s an organization. The Head Office & Plant is situated at 2km Defence road, Off Raiwind Road Lahore. Commercial production of dry milk powder was started
in 2000. The powder was introduced in the market in bulk form and in consumer packing. In year
2004, company lunched UHT packed milk and Desi Ghee in Tins. In order to improve its processes
and make the system more visible and to identify the shortcomings, Premier Dairies decided to
implement the concept of TQM. As an initial step, the management opted to acquire ISO 9000
certification. In 2000, it also started production of butter and ghee for its SHEREN MEHAL Outlets
with brand name "ANMOL". At start two types of powder were produced, SKIM Milk Powder &
FULL CREAM Milk Powder. Later in 2001, Premier Dairies launched VEGETABLE FAT FILLED
Milk Powder first time in Pakistan, which attracted many multinational companies.
Since 2000 Premier Dairies is working on the aspect of life to provide pasteurized milk in a healthy
way. We collect best milk from its reliable resources. After its careful and different checking
processes 'PURE & FRESH' milk is extracted and produced in the form of "VANIA" milk.

PRODUCTS
Vania Tetra Pack Milk:
Vania is a UHT (Ultra Heat Tested) milk which is safely packed under Six layers of solid tetra pack.
You can make sure that now high level of bacterias are very far from you which can easily damage
the health of young and old. Vania milk provides you the original, pure and fresh milk according to
the international standards.

Availability:

Packsize:250ml
Packs per tray:27packs

Tazadum Liquid Tea Creamer:

Tazadum Liquid Tea Creamer is a UHT (Ultra
Heat Tested) Liquid Tea Creamer which is safely packed under six layers of solid tetra pack. You
can make sure that now high level of bacterias are very far from you which can easily damage the
health of young and old. Tazadum Liquid Tea Creamer provides you the original, pure and fresh
Liquid Tea Creamer according to the international standards. 'Premier Dairies' arrange all these
factors of pasteurizing Liquid Tea Creamer being in the nature, rules and regulations, so that it is
called as "Gift of Nature".Tazadum Liquid Tea Creamer no doubts create a entirely different taste in
cup of coffee or a cup of tea.

Availability:

Packsize:250ml
Packs per tray:27packs

VaniaDesi Ghee:

VaniaDesi Ghee is a puredesi ghee with all natural available resources. VaniaDesi Ghee provides you
the origional, pure and fresh desi ghee. 'Premier Dairies' provides you a healthy life with pure
products like VaniaDesi Ghee so that it is called as "Gift of Nature". Vania Desi Ghee no doubt
creates a entirely different taste in your breakfast, lunch or dinner. We provide quality and health
depends on quality of diet. Balance diet formula is present in VaniaDesi Ghee. So we say it
"VaniaDesi Ghee is a Premier Product".

Available SKU's ;
Pack
Size
Packs Per Tray : 12 Tins

200

ml

Tin

Quantity per Tray : 12 x 200 ml = 2.4 Kgs

Vania Fruit Juices

Vania Fruit Juices are the fresh, healthy and tasty fruit juices. Available in Mango and Apple Flavours. You
can make sure that now high level of bacterias are very far from you which can easily damage the health of
young and old. 'Premier Dairies' arrange all these factors of fresh, healthy and tasty fruit juices, so that it is
called as "Gift of Nature". We provide quality and health depends on quality of diet. Balance diet formula is
present in Vania Fruit Juices. So we say it "Vania Fruit Juices is a Premier Product".

Available SKU's

Packsize:250ml
Packs per tray:27packs
Quantity per tray:6.75liters

RECEPTION OF MILK
Premiere Dairies has collection centres at 3 different cities of Punjab. This milk is sent to premier
plant through transportation vehicles,tankers. Some suppliers also collects milk and send it to plant
by their own means. This milk is first tested in reception lab after weighing. And price for milk is
paid on the basis of FAT and SNF quantity in milk which are done in the process lab. If and testsdone
in reception fail the milk is sent back and not received.

RAW MILK

In premiere dairies raw milk is obtained from

1. Cow
2. Buffaloe

Standards of Raw Milk:

1.
2.
3.
4.
5.

Fat
Protein
Lactose
Water
Ash(vitamins and minerals)

Price of Raw Milk:

Its price is paid on the basis of SNF which is determined by the LACTOMETRE READING.
Lactometer works on ARCHIMEDEs Principle ,which depends on the density of milk.

Skim milk :
When all fats are removed from milk.

Reception lab
Four types of test are performed in the reception lab after which milk is declared fit or unfit for
processing.

1-Oranoleptic tests

Taste

Smell and Color

2-Qualitative tests

Physical tests

Temperature test

Chemical tests

PH

Acidity test

3-Quantitative Tests

Fat test

Lactometer reading for SNF and TS

PROCESS LAB
The Following tests are performed in the process lab after the milk is processed.Fat and Snf tests are
also done for the raw milk .

Fat percentage
Moisture percentage
SNF percentage

Standards of premier dairies limited

UHT MILK:(vania)
PH

6.65-6.69

FAT

3.50%

LR

29.5%

SNF

8.90%

Tea Whitener:(Tazadum)
PH

6.65-6.69

FAT

6.00%

LR

15.00

SNF

5.79%

PASTEURIZATION
In this section raw milk is pasteurized , cream is separated from milk ,and passed to the U.H.T section
for further processing.
The following steps take place in the process of Pasteurization:

Balance tank:
From the silo milk comes in balance tank through a filter. Balance tank have a level controller, which
controls the quantity of in coming milk by a valve & maintain the level of milk as needed by the
process.

Regeneration Section 1

From balance tank milk goes to regeneration section.1, where the temperature of the milk is raised to
35-40oC by regeneration method. In regeneration section1 the raw milk & the hot milk coming after
pasteurization has counter flow.

Regeneration Section 2
Then the milk goes to regeneration section 2. It is also part of plate heat exchanger (PHE) in which
milk is heated to 55-65oc.

Heating Section:
In the heating section temperature of milk is increased to 85-90oc with help of hot water.

Holding Tubes:
Here milk stays for 15-20 seconds at 85-90oc, so that enzymes like phosphatase, peroxidase, lipase
etc. are inactivated and microbes are killed.

Separator:
From regeneration section 2 milk is passed to separator that will separate the extra butterfat from the milk in
the form of cream and it will also remove the unwanted material in the milk (Sludge). Separator works at
6000-7000 rpm . Due to centrifugal force, fat particles having less density are separated from the milk.
Impurities are also separated through the centrifugal action, as they settle down at the bottom, from where
these are disposeoff after every 15 minutes.

Homogenizer
From separator milk is again passed to the PHE where it is heated to a temperature between 70-80
after that dditional fats are added in the milk and the mixture is passed to homogenizer at high
pressure of 100-150 bar as a result fats are converted into smaller particles.

Regeneration no.2:
Now milk moves back in regeneration no.2. to warm the cold milk of balance tank. So in this way
energy is conserved. Here temperature of milk drops to 55-60oc.

Regeneration no.1
Pasteurized milk heated the incoming cool milk to save the energy. Here the temperature of the milk
drops to 35-40oc

Cooling Section:
In cooling section the temperature of the milk drops to 4-6oc by coming in contact with chilled water

UHT SECTION:

UHT (Ultra High Temperature) is a sterilization process, pasteurized milk is heattreated in a continuous flow
at a temperature of not less than 135C for few seconds followed by Aseptic Packaging. UHT plant in
Premiere Dairies has a capacity of 13000L/HR

Types OF U.H.T:

Upstream :
Heated at 30-37 degree c heating at 85 degree Chomogenizing at 85 degree cU.H.T at 135
degree ccooling at 85 degree c cooling at 30-37 degree c

Downstream:
U.H.T at 135 degree c cooling to 85 degree Chomogenizing at 85 degree c cooling at 30-37
degree c

Downstream U.H.T is being used in Premiere Dairies.

Process Steps:
Balance Tank:
From the storage tanks milk is passed to the balance tank of UHT plant where the level of milk is
controlled.

Pump:
It pumps the milk from balance tank to regeneration no.1

Regeneration Coil # 1:
It is part of Sterilizer which is a tubular heat exchanger with u-tubes at each end. In this section
temperature of milk raised to 70 by outgoing sterilized milk

Homogenizer # 1:
Here homogenization is done to break the fat clumps that formed during pasteurization and storage
under a pressure of 200-210 bar.

Regeneration Coil # 2:
Here the temperature of the milk is raised up to 120oc by out going UHT milk.

Heating Section:
Milk is heated to 135-140oc by indirect action of steam.

Holding Tubes:
Here the milk will stay for 2-3 seconds.

Regeneration Coil # 2:
From holding tubes milk comes to regeneration no.2 coil, where it is cooled to 120 oc by incoming
cold milk.

Homogenizer # 2:
It is done at 40 bar. Here the fat is uniformly distributed in the milk.

Regeneration Coil #1:

Milk is cooled to 80C by coming milk entering in the UHT plant from silo tank.

Chilling Section
Milk in this section is cooled to 24-30oC with the help of cold water.

TBA packaging material:

Polyethylene; Protect against outside moisture

Paper;For stability and strength.
Polyethylene; Adhesive layer
Aluminum foil; Oxygen flavor and light barrier
Polyethylene; Adhesion layer
Polyethylene; Seals in the liquid

Ghee Section

Ghee: Ghee is a hard fat that is obtained by heating butter made from the milk of a cow or a buffalo.

Ghee Manufacturing Process:

Fill ghee melters to about 800-900 kgs with butter.

Open steam valve of melters pressure at 1-1.5 bar. Steam button for ~10 hours.
Remove lassie and sludge from the bottom of the melters.
If moisture is 0.3%, then close the steam valve.
Open raw water valve of the melters to cool down the ghee to room temperatures.
Filter out ghee carefully into clean and dry plastic cans and cover the lids.
Then pack of ghee in 1kg tin and pouches. At the end, CIP occurs.

Juice:
Juice is the liquid that is naturally contained in a fruit or vegetable tissue. Juice is prepared by
mechanically squeezing or macerating fresh fruits or vegetables flesh without the application of heat
and solvent. In premiers dairies mango, apple, mix fruit juices are produced.

Juice process:

First we make batch in tanker B. Fill both A, B with hot water.

For batch we take this water small quantity in triblander by pump and some ingredient and
sugar pour in it. Then bland the ingredients. Then this mixture go to the tank B and A.
A motor attach with agitator in both tank who mix or agitate the solution thoroughly. Batch is
ready.
When process start, juice which is in tank A and B comes into the filter by pumps where it
filters all dust particle remove here.
After filter milk goes into the balance tank by feed pump. From balance tank feed pump take
juice and transfer to the PHE (plate heat exchanger).
In PHE juice comes in section where temperature is 60-65c this portion is regeneration
section. In this section juice heat ,temperature raise.
After this section juice come to the other section where the temperature of juice become 85c.
it is also regeneration section.
Juice heat in more in regeneration section, now it comes in more heating section, the
temperature of this section is 95c. in this section temperature of juice is more. Because in this
section one side of plate is more hot water circulate and one juice.
After this section juice goes to the holding tubes, in holding tubes juice stay 16sec in tube and
comes back to the regeneration section where it transfer heat of incoming juice and self
temperature of juice down and incoming juice temperature increase.

Ten after this section the juice comes into the booster pump where 1bar pressure is apply. And
then juice come into the other regeneration section (6065c) where it transfers the heat to the
incoming juice and self-temperature down.
At lesat juice comes into the PHE section 4. This is cooling section. In this section one side
cold water circulate and one side juice which is come into the regeneration section. In cold
section temperature will become 30c.
After this section juice goes to for packaging in packaging room by pipe lines, juice pack in
tetra pack pouches.

Powdered Milk Plant

Powdered milk is produced by extracting water and fat from fresh pasteurized milk.During the water
extraction process, beneficial nutrients such as amino acids are sustained.In this plant two main
equipments are used i.eevaporator and drier.First of all pasteurized milk is sent to the evaporators.

Evaporators:
Evaporation is a highly energy efficient way of removing water or other liquids and thus the primary
process for the production of concentrates. Process time can be shortened by distributing the liquid to
a greater surface area, or by a higher temperature.Evaporator used in Premier Dairies is triple effect
evaporator.

Double Stage Drying Plant:

A spray dryer is a device used in spray drying. It takes a liquid steam and separates the solute or
suspension as a solid and then solvent into vapor. The solid is usually collected in a drum of a
cyclone. The liquid input stream is spray through a nozzle into a hot vapour steam and vaporized.
Solids form as moisture quickly leaves the droplets. A nozzle is usually used to make the droplets as
small as possible, maximizing heat transfer and the rate of water vaporization. Spray dryers can dry a
product very quickly compared to other methods of drying. They also turn a solution or slutty into a
dried powder.

Drying Milk in Spray Dryer:

The plant specially designed for the drying of skim milk and is prepared for additional equipments for
whole milk production. The plant consists of a spray dryer in connection with a fluid bed. There is a
two stage drying process. Major part of the moisture is removed in first stage of spray dryer and
remaining part of the moisture is removed in second stage of fluid bed dryer. Concentrated products
comes from storage tank into the pre heater by pump where milk heats and goes to heater where all
dust particles in milk separated.From filters, milk comes into the header by high pressure pump
which have pressure 200-210 bars.Hot air can be produced by steam radiator, air is sucked by blower,
when this normal air is sucked with the steam at 180-190 Celsius temperature, then air obtains this
temperature and hot air is introduced in the main chamber along with the panel header which sprayed
into the main chamber at 200-210 bars.

Boiler section
This section supply steam to the dairy section. steam is required for evaporation of water from milk to
Manufacture skim milk powder also hot water is required to heat the skim milk in pasteurization
process and water.U.H.T section also require the steam to heat the milk at 135 degree C. The section
is supervised by boiler charge man and there are boiler attendants to operate the boiler in each shift.
In primer dairy two boilers are being used and both are fire in tube boilers
Furnace oil boiler
Burners boiler
In furnace oil boiler furnace oil burn and is operate by gas .But burner boiler operates by burning the
wood. Function of burners same but capacity is different. Burner oil works when gas is not available.
capacity of the boiler is 13 tons. Mean 13 tons can be converted into stream per hour. Pressure in
boiler is 17 bar (1 bar 14.5 psi )50 tubes of 145 and 18 ft in furnace boiler.

At 17 C of saturated steam
70% moisture in wet steam
0.05% moisture in saturated steam No moisture in super heated.

Three sections in boiler

Primary burners
Tubes chamber
Smoke chamber

Principles of boiler:
To produce steam by using water of zero hardness

Working of boiler:

First oil comes in the storage tanks which have capacity 50,000 liters, by pump oil comes into
service tanks where the temperature of oil becomes 90Centigrade because in this tank oil is
heated up. The pressure of furnace is set to 1 bar.
The filtered this oil and through pump oil comes into the oil header of boiler. from oil header
oil come in burner by feed line through valve and excess oil return service tank by return
valve.
In burner(svirling chamber) a rotary cup here this portion is pass 1 in this section a motor is
apply on upper side from operating motor it rotates 6000 RPM to perform atomization ,
showering of air and oil mixture in this portion and 1 side flame apply (18000 volts) for
sparking and sparking for 10 second and combustion starts. Flute is part where flame
complete and burnt. A photocell is here outside the camber to detect the slightly flame.
By burning gases produces in boiler tubes. This section is pass two. Gases produces in tubes
and water outside the tubes which is comes in boiler by outside storage tank of water.
After pass two gasses heat the water in pass three and gasses go out by chimneys and upper
portion of boiler steam is produce 250 psi.
Then by valves steam out in the plant where it is used.

CLEANING IN PROCESS

Definition:
CIP is removal of milk particles and lowering the microbial load in the production line & in the raw
milk tankers by using various types of cleaning agents (acid, base & water) and temperature.

Function Of Various Cleaning Agents In CIP:

Lye(liquid form of NaOH) for removal of fat residues.

Acid for the removal of protein matter

Hot water for the removal of residues and salt.

Acid and hot water also used for lowering microbial load.

C.I.P STEPS

Water rinsing (pre rinsing)

Alkali rinsing
Water rinsing
Acid rinsing
Water rinsing

Types
Two types of CIP are done in premier dairies,
1- Short CIP (40 min)
2- Long CIP (70 min)