Milk, liquid secreted by the mammary glands of female mammals to nourish their young for

a period beginning immediately after birth. The milk of domesticated animals is also an
important food source for humans, either as a fresh fluid or processed into a number of dairy
products such as butter and cheese. Milk is a nutritious choice as it provides nine essential
nutrients our body needs. Milk contains essential nutrients like high-quality protein,
calcium, vitamin D and more. These nutrients help our bodies function properly. For
example: Protein helps build and repair muscle tissue Calcium and vitamin D helps build
and maintain strong bones and teeth Milk also contains B vitamins, which can help your
body convert food into energy.
Dairy Industry in India India:
India is leading milk producing country in the world, accounting for 19 percent of the
global market share and expected to grow at compound annual growth rate (CAGR) of
14.8% between FY 2018 – 2023. As per fiscal year 2019, milk production in India amounted
to about 187 million metric tons. As per FY – 2018, around 81% of the Indian dairy and
milk processing market comes under unorganized sector, where milk is processed in
unhygienic infrastructure, which affects the overall quality of milk and milk-based products.
Consumption patterns of liquid milk at the farm level and less infrastructure for processing
is the main reason for low value addition50 of milk. The demand for value added products
especially traditional dairy products is increasing day by day and the dairy industry of the
country is trying to meet the present demand. Uttar Pradesh, Rajasthan and Gujarat are the
major milk producing states inIndia. Uttar Pradesh is the largest milk-producing state, as it
has the highest buffalo populationand the second-highest cattle population in the country.
Majority of the rural population in this state is engaged in livestock nurture and dairy
farming. Gujarat holds several cooperative dairy unions, milk cooperative societies and
private dairy plants, which play vital roles in the production of milk and milk-based
products in the state.

Insight on value-added product:

Apart from processed liquid milk, Indian dairy and milk processing industry generates
revenue from several value-added products such as butter, curd, paneer, ghee, whey,
flavoured milk, ultra-high temperature (UHT) milk, cheese, yogurt, dairy whitener and
milk powder. During the FY 2016 – 2020, the market size of dairy ingredients is expected
to grow by around 14%.
Export-import opportunities
The export of dairy products from India has increased to countries like Bhutan,
Afghanistan, Canada, Egypt, and the United Arab Emirates. India has also imported a
significant number ofdairy products from countries like France, New Zealand, Ireland,
France, Ukraine, and Italy.

Key deterrents to the growth of the market:

Despite having a significant livestock base of milch animals, India lacks in terms of good
processing facility and availability of cold storages which results in wastage of dairy
output. Lack of sufficient storage facilities and inefficient distribution channels are
hampering the growth of the Indian dairy and milk processing industry. Sufficient
quantity and good quality
of feed and fodder are required for proper animal rearing and milk production. Improper
droughts and flood management affect the production of fodder in India. Deficiency of
proper feed and fodder for milch animals, due to high usage of agricultural crop residues by
producersof fiber board, paper, and liquid fuels, affect its availability for dairy production
and milk processing.
Need for Processing Milk:
Milk is considered wholesome food mainly because of its high nutritive value. It has to
be processed to Increase the shelf life, because it is highly perishable, Prepare value
added products like peda, dahi, cheese, paneer, butter, ghee, AMF, flavoured milk,
cheese, and yogurt, dairy whitener, milk powder etc. and many more dairy based
products, for a good health and, Make business out of it, create job opportunities,
consequently building financiallystrong Nation.
15% of total milk production across the nation is distributed under cooperatives and
private dairy Processing Plants. These statistics exhibit a wide scope for young
entrepreneurs to invest in the processing of milk and manufacture of dairy products for
both domestic and export.
Considering the above need of milk processing, Abhinav Dairy Milk Processing Plant
was established in the Year 2021 in the premises of Abhinav Dairy Farm, situated in
Village Charba (Dhaki), Block Sahaspur, Disttt. Dehradun. This Milk Processing Plant
has the capacity to process 5000 Liters of raw milk per day. Given below is the process
flow adopted at Abhinav Dairy Processing Plant:-

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 Milk Procurement:
Milk drawn from the cattle remains almost sterile with the milk temperature of about 37°
C equal to the body temperature of the milch animal. The fresh milk will have a shelf life
of about 2 to 3 hours and starts to sour. Milk is a perishable commodity gets easily
contaminated from air, utensils, and other reasons; the milk should be sent to the dairy
Processing Plant or milk collection centres at the earliest. In almost all countries, most of
the milk is produced inrural regions which are transported to the milk processing plant.
At Abhinav Dairy Processing Plant, milk is collected both in the morning and evening and
is transported twice in a day. Procurement of milk is carried out in various ways depending
on the location and availability of collection centres or dairy Processing Plants. Milk is
collected at the dairy Processing Plant by the following methods:
1. Individuals: Those that are located near to the milk collection centre, the milk is brought
by individual producers directly. The individuals carry the milk on their own transport and
vessels to the Dairy plant.
2. Contractor: Some contractors collect milk from individual milk producers. The contractor
supplies milk to the dairy plant. In this process, the contractor has to collect and transportthe
milk, thereby the contractor buys milk at a cheaper rate from the individual milk produced
and keeps his share of profit.
3. Cooperative Organizations: To avoid the middlemen and contractors; some individual milk
producers formed as a cooperative organization. Milk is collected at the cooperative
organization brought by individual milk producers; the cooperative societies or

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 organization is responsible to supply milk to the dairy plant. This method is beneficial to
individual producers as they don’t need to share profits with contractors or middlemen.
4. Milk Collection cum Chilling Centres: This method is currently adopted in Abhinav dairy
operations. The milk that arrives at the collection centers brought by individuals from the
nearby rural regions is weighed and tested for fat content. The milk is stored in 40 l cans
and sent to the milk chilling center or dairy Processing Plant.
Milk Processing:
Milk is a nutritious food having a short shelf-life as it is a highly perishable commodity
and anexcellent medium for bacterial pathogens and micro-organisms growth. The shelf-
life of milk can be extended for several days or weeks through milk processing that helps
in reducing the number of pathogenic microorganisms. Following are the milk processing
steps:
1. Skimming: The raw milk during pasteurization undergoes milk skimming through common
centrifugal separator application; the milk is passed through a clarifier or a separator which
spins the milk through a series of conically shaped disks. The purpose of this process is to
separate the debris, skim milk, and cream. Clarifier removes debris and any sediment present
in the raw milk. The separator separates the heavier milk fat from the lighter milk at a
temperature between 45° to 55° C to produce cream and skim milk.
2. Fortifying: The skimmed milk may be added with Vitamins A and D at this stage. A
peristaltic pump helps in dispensing the required amount of vitamin concentrate into the
milk.
3. Pasteurizing: This is an important process stage in milk processing. Heating every particle
of the milk for a specified time duration at a specific temperature is termed as pasteurization.
Usually, it can be carried in two ways; first, the temperature can be 72°C for 15 to 17 sec
time period or 63°C for 30 minutes. Pasteurization process helps in destroying bacteria and
other microorganisms that may affect the milk shelf-life and also may affect consumer’s
health.
4. Homogenizing: In this process, the size of the remaining milk fat particles is reduced evenly.
Homogenizing helps to prevent the milk fat from separating and floating to the surface. After
going through pasteurization, the hot milk is pressurized to 2,500 to 3,000 psi
by a multiple-cylinder piston pump and then compelled to pass through tiny sections in an
adjustable valve. When the fat particles break down evenly into the proper size, to avoid
harming its taste, the milk is quickly cooled to 4°C.
5. Packaging: The final stage in the dairy Processing Plant is packing. The milk is packed in
500ml and 1000ml sealed packets. The packets are stamped with the date of packing. The
milk packets are placed in transport containers and refrigerated. Transporting of milk
packets to various retail outlets and distribution centers in Dehradun is carried out in
refrigerated vehicles and are kept in refrigerated display cases.
Manufacturing of Dairy Products:
Abhinav Dairy Processing Plant manufactures the following Dairy Products-
Curd (Dahi) Production:

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Dahi is a set-type fermented dairy product originated in the Indian Subcontinent. Dahi is the well-
known product since from ancient time and misti dahi is popular in eastern region. Consumption of
fermented milk products is associated with several types of human health benefits partly because of
their content of lactic acid bacteria. Dahi has valuable therapeutic properties and helps in curing
gastrointestinal disorders. Dahi added with probiotic bacteria enhances its health benefits such as
immune enhancement, blood pressure reduction, antiatherogenic effect, antidiabetic effect,
anticarcinogenic effect, antioxidative effect and curing of gastrointestinal disorders.
At Abhinav Dairy Plant following SOPs are followed for Curd Production-
1. Raw Milk Reception: The Raw Milk received in tankers/food grade barrels is weighed either in
weighbridge or in weighing bowl Batch wise and subject to sampling & testing for its parameter as
per specified and defined procedures.
2. Filtration: The accepted milk is weighed and unloaded in the Dump Tank and Pumped through a
chiller after properly filtering, such milk is stored in the silos through the previously cleaned,
sterilized/ steamed pipeline, and silos etc.
3. Chilling: Filtered milk is chilled through a chiller ensuring the temperature not more than 5 deg.
Chilled milk is stored in the silos through the previously cleaned, sterilized/ steamed pipeline, silos
etc.
4. Standardization of Milk: Milk Pasteurization and Standardization of milk is planned as per product
requirement and fat & SNF is maintained.
5. Homogenization and Pasteurization: Homogenization of milk is done at 150/50 bar in two stages
and then Pasteurization at 950C by passing through automatic holding tube for 6 mins and cooling to
40C. Milk is then transferred to storage tank.
6. Inoculation and culture addition: Now transfer the milk to inoculation tank through PHE for heating
milk at 420C. Take appropriate quantity of milk so that filling is over in one hour. Culture addition is
done at recommended doses.
7. Filling and Sealing: Milk with culture is filled in required packing sizes and stacked in trolleys.
8. Incubation: Trolleys then moved to incubation room maintained a temperature of 42±20C.
Incubation is done for 4 to 6 hours till pH of 4.7±0.5 is achieved.
9. Blast Cooling: As soon as pH is achieved, trolleys are transfer to blast cold room at zero degree with
direct blowers so that the product temperature of 100C is achieved within 3.5 to 4 hrs mins.
10. Cold Storage: After 3.5 - 4 hrs transfer the trolleys in cold storage under 50C till the time of dispatch.
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11. Dispatch: Product is dispatched in refrigerated trucks and vans maintaining a temperature of below
50C.

Butter Production:
Raw milk after undergoing the process of {filtration/clarification, skimming, and
pasteurization are now ready to start the butter production process. Milk that is
homogenized is not good for butter production, avoid the homogenization process. After
skimming, the heavier milk fat that is separated is from raw milk is heat treated and cooled.
This helps good whipping and churning. At the time of churning, culture inoculation can be
processed for the ripening of the milk. This helps increase the content of diacetyl, which is
the compound responsible for the flavour of butter. Butter made without culture is called sweet
cream butter, butter that is flavor enhanced using culture is termed cultured butter or lactic.
Both sweet cream and cultured butter have less storage life. To add flavor and storage life,
salt is added at the recommended dosage. Butter which is ready can be stored in bulk
quantities to be repacked into regular market quantity or according to market demand.

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 Cheese Production:
Milk is heated while being stirred in the large cheese tank until it reaches the desired
temperature. Add lactic acid bacteria along with rennet an enzyme to the milk. Stop
stirring at this point, allowing the milk to settle down in a large vat. 30 to 45 minutes of
resting leads to curdle of milk. The jellylike curdled milk is stirred in breaking it into
smaller pieces. This allows separation of curd and water content. The smaller the pieces
the harder the cheese will be. The curd is stirred while being heated up to 57° C. The
cheese is collected in cheesecloth and pressed hard to remove whey or water content. The
soft cheese collected is put into a saline bath for 30 minutes to 2 days depending on the
cheese size. This processes any leftover moisture content and allows absorption of salt to
make the cheese stable. The last process is ripening and fermentation, this makes the
cheese dough formation of holes and the aroma.

Ghee Production:
Ghee production is the largest segment of milk utilization in India. Abhinav Dairy
Processing Plant has Ghee production facility to meet the demand of the market as well
as to utilize the excess fat in profitable manner. Since simple technology involved in ghee
production and relatively less investment for ghee production unit as already plant has the
steam boiler facility. Abhinav Dairy Processing Plant follows Creamery Butter Method.
This is the standard method adopted in most of the organized dairies. Unsalted or white
butter is used as raw material. Butter mass or butter blocks are melted at 60°C to 80°C in
butter Melter. Molten butter is pumped into the ghee boiler where final heating will be
done using steam as heating medium. Increase the steam pressure to raise the temperature.
Scum which is forming on the top of the surface of the product is removed from time to
time with the help of perforated ladle. Moment of disappearance of effervescence,
appearance of finer air bubbles on the surface of the fat and browning of the curd
particles indicates to stop heating. At this stage typical ghee aroma is produced. Final
heating temperature is adjusted to about 114±2°C. To get the cooked flavour, heating
beyond this temperature is also being in practice. Ghee is filtered via oil filter into the
settling tank.

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 Processing Plant Equipment and Machineries:
Based on the type of milk procured and products manufactured different plant and
machineryare required for dairy processing. All the plant and machinery are according to
BIS specifications. The dairy Processing Plant for 5,000 liters capacity and section-wise
machinery required with specifications are given below:
Reception Section of Dairy Processing Plant Equipment and
Machinery:
S.No Particulars Qty
1. Can Roller Conveyor (3 mtrs) 1 No.
2. Can Tip Bar 1 No.
3. S.S Weigh Bowl (500 lits) Electronic 1 No.
4. S.S Dump Tank (1000 lits) 1 No.
5. S.S Milk Pump (1.5 HP) 1 No.
6. Disc Filter 1 No.
7. S.S Can Scrubber 40 ltrs 1 No.
8. Can Drip Saver (6 cans) 1 No.
Laboratory Equipment: (Milko scan, Density meter,
9. Milko tester, Cryoscope, Emulsion quality analyzer, 1 set each
glassware, etc)
Process Section of Dairy Processing Plant Equipment and Machinery:
S.No Particulars Qty
1. S.S Milk pump (2 HP) 1 No.
2. S.S Milk Chiller, Cap (3 klph) 1 No.
3. S.S Balance Tank with Float (100 lts) 1 No.
4. S.S Flow Control Valve 1 No.
5. S.S Simplex Filter 1 No.
6. S.S Remote Control 1 No.
7. Milk Pasteurizer (2.5 klph) 1 No.
8. S.S Holding Coil (16 secs) 1 No.
9. S.S Pipeline & Valves (interconnecting) 1 Set
10. Flow Diversion Valve 1 No.
11. Cream Separator (500 l/hr) 1 No.
12. Cream Tank (1 kl) 1 No.
13. Ghee Boiler (250 ltrs) 1 No.
14. Ghee Settling Tank (250 ltrs) 1 No.
15. Ghee Balance Tank & Pump 1 Set
16. CIP Unit 1 Set
Storage and Packaging of Dairy Processing Plant Equipment and
Machinery:
S.No Particulars Qty
1. HMST- MS Outer (5 kl – single comp) 1 No.
2. HMST- MS Outer (10 kl – single comp) 1 No.
3. S.S Milk Pump (1hp) 1 No.
4. S.S Overhead Tank (200 ltrs) 1 No.
5. Packing Machine (5000 pph) 2 No.
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 6. SS Pipes & Valves (interconnecting) 1 Set
7. Pouch Packing Machine (stabilizer) 1 No.
8. Spare S.S Pump (tanker filling) 1 No.
9. G.I Pipeline (Driers for air & controls) 1 Set
Utilities of Dairy Processing Plant Equipment and Machinery:
S.No Particulars Qty
1. Hot Water Generator 1 No.
2. Water Softener 1 No.
3. G.I Pipeline (water pump & valves) 1 No.
4. Chimney (3 mtrs) 1 No.
5. Makeup Water Tank (200 ltr) 1 No.
Refrigeration Section of Dairy Processing Plant Equipment and
Machinery:
S.No Particulars Qty
1. Refrigeration (storage equipment) 1 Set

Electricals of Dairy Processing Plant Equipment and Machinery:

S.No Particulars Qty

1. Generator (63 kva) 1 No.
2. Cables & Others 1 Set
3. MCCB Control Panel Board 1 No.

Staff for Dairy Processing Plant:

S.No Particulars No’s
1. Plant Manager 1 No.
2. Plant Operator 1 No.
3. Marketing 2 No.
4. Plant Supervisor 1 No.
5. Mechanics 2 No.
6. Driver (Delivery) 1 No.
7. Lab Technicians 1 No.
8. Labor 4 No.
9. Accounts Staff 1 No.
10. Watchman 2 No.

Marketing of Milk and Dairy Products:

Abhinav Milk Processing unit has a marketing department that promotes milk and dairy
products by placing hoardings or billboards at strategic locations in the cities and retail
centres. A detailed market survey of cities and retail outlets undertaken at the beginning
helped with distribution and advertising plans. The major competitors and their present
offers are found out at regular intervals. Building or promoting dairy brand milk parlors
and distribution retail outlets in major densely populated regions in the cities with door
delivery of milk to consumers helps to achieve higher growth in sales.

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 Dairy Processing Plant– Statutory / Government Approvals
Dairy Processing Plant possess the following requirements licenses and permits from statutory
agencies:
 License from the State Food and Drug Department.
 MMPO registration from the concerned state government.
 Plan approval from Gram Panchayat or Municipality.
 Registration – PF, ESI, and Labor laws.
 NOC from Fire and Safety Department.
 Clearance Certificate from Pollution Control Board
 Registration with Small Industries or District Industries Department.
 License from Factory Inspector for Boiler Installation.

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