ANNA UNIVERSITY REGIONAL CAMPUS - TIRUNELVELI

INDUSTRIAL TRAINING REPORT

Submitted by

IJAZ AHAMED.S

In partial fulfillment of the requirement for the award of course

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

2022-2026

JULY - 2024

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ANNA UNIVERSITY REGIONAL CAMPUS – TIRUNELVELI

BONAFIDE CERTIFICATE

Certified that the internship report “TIRUNELVELU DISTRICT CO-

OPERATIVE MILK PRODUCERS UNION LTD.” is the bonafide work of IJAZ
AHAMED S (950022114018) who carried out the summer internship under my
supervision. Certified further that the best of my knowledge the work reported here in does
not form part of any other or dissertation on the basis of which a degree or award was
conferred on an earlier occasion on this or any other candidate.

COURSE COORDINATOR HEAD OF THE DEPARTMENT

Dr. S. RAJAKUMAR, B.E., M.Tech., Ph.D., Dr. S. RAJAKUMAR, B.E., M.Tech., Ph.D.,
Assistant Professor & Head of Department, Assistant Professor,
Department of Mechanical Engineering, Department of Mechanical Engineering,
Anna University Regional Campus, Anna University Regional Campus,
Tirunelveli 627007. Tirunelveli 627007.

Submitted for the viva examination held on ……………………………

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 ACKNOWLEDGEMENT

I would like to express my sincere gratitude to the entire team at Tirunelveli

District Co-operative Milk Producers Union Ltd. for giving me the opportunity
to undergo industrial training. The knowledge and practical experience gained
during this period have been instrumental in understanding the processes of
milk production and distribution. I am thankful for the guidance and support
extended by the employees and officers during the training period, which has
significantly contributed to my professional development.

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 ABSTRACT

This industrial training report provides an overview of the 15-day

internship conducted at Tirunelveli District Co-operative Milk
Producers Union Ltd. The training offered practical exposure to the
application of mechanical engineering principles in the dairy industry.
Key activities included milk collection, processing (pasteurization and
homogenization), quality assurance, packaging, logistics, and
equipment maintenance.

The internship emphasized the importance of adhering to FSSAI

standards, preventive maintenance, and the use of automation for
operational efficiency. A SWOT analysis was conducted to evaluate
the cooperative’s strengths, weaknesses, opportunities, and threats.
Sustainability initiatives, including energy optimization and waste
management, were also explored.

This report highlights the learning outcomes, including technical

skills, teamwork, and problem-solving abilities, along with
recommendations for process improvements. The internship bridged
theoretical concepts with industrial practices, enhancing
understanding of dairy processing and its associated challenges.

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 STUDENT PROFILE

NAME: IJAZ AHAMED S

SEMESTER: 5

COURSE: BACHELOR OF ENGINEERING IN MECHANICAL

ENGINEERING

BATCH: 2022–2026

ROLL NUMBER: 950022114018

INTERNSHIP DURATION: 15 DAYS

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 TABLE OF CONTENT

S.NO TITLE PAGE NO

1. INDUSTRY PROFILE 5

2. DAILY PROGRESS IN INDUSTRIAL 6

TRAINING

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3. SWOT ANALYSIS

4. LEARNING OUTCOMES 19

5. CONCLUSION 26

6. TRAINING CERTIFICATE
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1. INDUSTRY PROFILE
The Tirunelveli District Co-operative Milk Producers Union Ltd. is a
cornerstone of dairy production and distribution in the Tirunelveli district.
Established to empower local dairy farmers, the cooperative focuses on
delivering high-quality milk and dairy products while ensuring fair
compensation for its members.

Key Highlights:

 Location: Reddiyarpatti Road, Tirunelveli

 Primary Functions: Milk collection, processing, packaging, and
distribution.
 Organizational Structure: Includes divisions for procurement,
processing, quality control, and distribution.
 Machinery Used: Pasteurizers, homogenizers, chilling tanks, and
packaging units.

Contribution to the Economy:

 Ensures fair pricing for farmers.

 Enhances local employment opportunities.
 Provides high-quality dairy products to consumers

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2. DAILY PROGRESS IN INDUSTRIAL TRAINING

DAY 1: ORIENTATION AND INDUSTRY OVERVIEW

The first day started with a detailed orientation session, where we were
introduced to the cooperative’s mission and operational workflow. The
management team explained how the cooperative supports local dairy farmers
by ensuring fair pricing and creating a streamlined system for milk collection,
processing, and distribution.

We were briefed on the different departments within the facility, including

Procurement, Processing, Quality Control, Packaging, and Distribution. This
session highlighted the key role mechanical engineering plays in maintaining
the facility’s equipment and ensuring smooth operations.

Key learning included:

 Understanding the importance of dairy cooperatives in rural development.

 Realizing how engineering contributes to food safety and efficiency.
 Observing the workflow from milk collection to delivery.

DAY 2: MILK COLLECTION PROCESS

Milk collection was observed at various collection points where farmers deliver
fresh milk. Each collection point had standardized equipment to test milk for fat
content, acidity, and freshness.
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I witnessed the use of lactometers to measure milk density and simple chemical
tests to detect any adulterants. Cold storage facilities at these points were
emphasized to preserve milk quality during transportation to the central
processing unit.

Detailed observations:

 Importance of maintaining a cold chain to avoid spoilage.

 Logistical challenges in collecting milk from rural areas.
 The role of data logging systems in tracking milk quality and quantity.

DAY 3: PASTEURIZATION AND HOMOGENIZATION

Pasteurization and homogenization were two critical processes that I observed

in detail. During pasteurization, milk is heated to a specific temperature to
eliminate harmful microorganisms, followed by rapid cooling to preserve its
nutritional value.

Homogenization, which prevents cream separation, was conducted using high-

pressure systems. I assisted in monitoring temperature, pressure, and flow rates
during these processes. The engineers also explained the significance of heat
exchangers and flow pasteurizers in ensuring energy efficiency.

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DAY 4: QUALITY TESTING

The quality testing process ensured the safety and compliance of the milk and
its derivatives. We used advanced laboratory equipment to measure microbial
loads, pH levels, and contamination.

I actively participated in tests such as:

 Methylene blue reduction test to determine microbial activity.

 Fat percentage analysis using Gerber’s method.
 Adulterant tests for starch, urea, and detergent residues.

This day emphasized the precision required in maintaining FSSAI (Food Safety
and Standards Authority of India) compliance standards.

DAY 5: PACKAGING TECHNIQUES

On this day, I explored the fully automated packaging line, where milk was
sealed, labelled, and batched for distribution. The machines were equipped with
sensors for weight monitoring and error detection.

We studied various types of packaging based on market needs, such as small

sachets, bottles, and tetra packs. I assisted in addressing issues like incorrect
labelling and faulty seals.

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DAY 6: EQUIPMENT MAINTENANCE

The maintenance of critical equipment was the focus of the sixth day. Tasks
included inspecting pasteurizers for thermal leaks, cleaning homogenizers to
remove residue, and lubricating conveyor belts.

Key learning:

 Identifying early signs of equipment wear and tear.

 Using preventive maintenance techniques to reduce downtime.
 Understanding the role of CIP (Cleaning-in-Place) systems for hygiene.

DAY 7: LOGISTICS AND DISTRIBUTION

I accompanied the logistics team to understand how processed milk is delivered

to wholesalers and retailers. Milk tankers were equipped with insulated
containers to ensure temperature control during transit.

Challenges observed:

 Delays caused by traffic congestion.

 Managing supply-demand variations, especially during festive seasons.
 Importance of route optimization to save fuel and time.

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DAY 8: AUTOMATION IN DAIRY PLANTS

This day focused on the role of automation in improving efficiency.

Programmable Logic Controllers (PLCs) monitored operations like temperature
control, pasteurization timing, and packaging speed.

Tasks included:

 Observing real-time data analytics for system optimization.

 Understanding the use of SCADA (Supervisory Control and Data
Acquisition) systems for remote monitoring.
 Gaining insights into troubleshooting automated systems.

DAY 9: ENERGY AND RESOURCE OPTIMIZATION

Energy efficiency was emphasized on this day, where I studied how the plant
minimizes power consumption. Heat recovery systems were installed to reuse
waste heat from pasteurization processes.

Key learning:

 Techniques to reduce water wastage in cleaning processes.

 Renewable energy integration, such as solar panels for lighting.
 Evaluating energy consumption patterns to identify inefficiencies.

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DAY 10: WASTE MANAGEMENT IN DAIRY PRODUCTION

This day involved learning about managing by-products and waste. The plant
reused whey for animal feed and recycled wastewater after treatment.

Key observations:

 Effluent Treatment Plants (ETPs) ensure that wastewater meets

environmental standards before disposal.
 Packaging waste was segregated and sent for recycling.
 The importance of adhering to sustainability protocols.

DAY 11: EQUIPMENT INSPECTION AND CALIBRATION

Equipment calibration ensures the accuracy of machines used in quality control

and production. I participated in calibrating thermometers, pressure gauges, and
lactometers.

Key takeaways:

 Ensuring precise measurements during pasteurization and

homogenization.
 Identifying calibration errors and rectifying them to maintain compliance.

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DAY 12: PRODUCT SAMPLING AND TESTING

Sampling of products like milk, curd, and butter was performed to ensure they
met quality standards. Sensory tests were conducted to check for taste, smell,
and consistency.

Tasks included:

 Testing curd for lactic acid bacteria.

 Analyzing butter for fat content and texture.
 Studying shelf-life parameters through accelerated storage tests.

DAY 13: DOCUMENTATION AND RECORD-KEEPING

Record-keeping is essential for traceability and compliance. I observed how

data for milk batches, quality test results, and dispatch schedules were
maintained.

Key insights:

 Using digital systems for storing and analyzing data.

 Importance of accurate documentation during audits.

DAY 14: DISCUSSION ON CHALLENGES IN DAIRY OPERATIONS

A group discussion was held with supervisors and fellow trainees to address
challenges such as:
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  Dealing with equipment failures during peak demand.
 Ensuring product quality despite seasonal variations.
 Reducing costs without compromising safety.

DAY 15: FINAL REVIEW AND FEEDBACK

The last day was dedicated to reviewing my performance during the training.
Supervisors provided constructive feedback on my technical skills and ability to
adapt.

I shared my insights and suggestions for improving processes, such as adopting

more advanced automation tools and focusing on renewable energy sources for
future expansion.

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3. SWOT ANALYSIS
STRENGTHS

1. Modernized Equipment and Facilities

o The cooperative employs advanced machinery like pasteurizers,
homogenizers, and automated packaging lines, ensuring high-quality
products and efficient processing.
o Example: Automated CIP (Cleaning-In-Place) systems maintain
equipment hygiene without interrupting production.

2. Strong Farmer Network

o A wide network of dairy farmers provides a steady supply of milk,
strengthening the cooperative’s supply chain.
o Example: Local farmers benefit from fair pricing and support for
veterinary services.

3. Commitment to Quality Standards

o The organization adheres to FSSAI guidelines, ensuring safe and
hygienic products. This builds consumer trust and market
credibility.
o Example: Quality checks at every stage—milk collection,
pasteurization, and packaging—ensure premium product delivery.

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WEAKNESSES

1. Seasonal Variations in Milk Supply

o Milk production often fluctuates due to seasonal factors, leading to
inconsistencies in supply.
o Example: Reduced milk yield during summer months due to heat
stress in cattle.

2. Limited Value-Added Products

o The cooperative focuses mainly on milk and basic dairy products,
missing out on high-margin value-added products like cheese,
flavored milk, and yogurt.
o Example: Private competitors offer a wider range of premium
products.

3. Dependence on Manual Labour

o Certain operations, like milk collection and testing, still rely on
manual processes, which can lead to inefficiencies.
o Example: Delays caused by manual quality testing at multiple
collection points.

4. Infrastructure Limitations in Rural Areas

o Poor roads and lack of cold storage facilities at collection centers
pose logistical challenges.

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 o Example: Spoilage risk during transportation due to insufficient
refrigeration.

OPPORTUNITIES

1. Expansion into Value-Added Products

o Diversifying into products like cheese, ice cream, and pro-biotic
drinks could tap into growing consumer demand.
o Example: Urban markets increasingly favor ready-to-eat dairy
products for convenience.

2. Adoption of Renewable Energy

o Solar energy and biogas systems could reduce operational costs and
enhance sustainability.
o Example: Solar panels for water heating during pasteurization or
using cow dung to produce biogas for energy needs.

3. Government Support
o Subsidies and schemes promoting the dairy sector provide an
opportunity for growth.
o Example: Access to funds under the National Dairy Development
Program (NDDP) to upgrade infrastructure..

4. Technological Advancements
o Adopting IoT-based monitoring systems and AI for predictive
maintenance could improve efficiency.
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 o Example: Sensors in milk tanks to monitor temperature and detect
spoilage in real-time.

THREATS

1. Competition from Private Players

o Large private dairy companies with extensive product portfolios and
aggressive marketing strategies pose a significant challenge.
o Example: Brands like Amul and Nestlé dominate the urban market
with their innovative offerings.

2. Market Price Volatility

o Fluctuations in raw milk prices can impact profitability, especially
when procurement costs rise but retail prices remain stable.
o Example: Droughts leading to a surge in feed costs and reduced
milk production.

3. Stringent Regulatory Requirements

o Adhering to evolving food safety and environmental regulations can
increase compliance costs.
o Example: Mandates for zero-waste facilities and reduced carbon
footprints.

4. Logistical Challenges
o Ensuring timely delivery and maintaining freshness during transit is
a constant threat, especially in remote areas.
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o Example: Traffic disruptions or equipment failure in refrigerated
vehicles.

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4. LEARNING OUTCOMES
1. Technical Knowledge and Practical Skills

 Gained insights into dairy processing equipment: Observed and

operated advanced machinery like pasteurizers, homogenizers, and
chillers.
o Example: Learned how plate heat exchangers work to maintain the
pasteurization process's efficiency and hygiene.
 Equipment troubleshooting: Identified minor mechanical issues in
conveyor belts and sealing machines, assisting in their resolution.
o Example: Replaced a malfunctioning valve in a pasteurizer with the
guidance of a supervisor.

2. Understanding of Quality Assurance Protocols

 Importance of maintaining high standards: Learned how to test milk

and other dairy products for pH levels, microbial activity, and adulterants.
o Example: Participated in performing the methylene blue reduction
test to measure bacterial load in raw milk.
 FSSAI compliance: Understood the importance of adhering to food
safety norms and their role in building consumer trust.
o Example: Assisted in documenting batch quality reports for
regulatory audits.

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3. Hands-On Experience in Maintenance Operations

 Preventive maintenance: Gained experience in routine servicing of dairy

equipment to ensure smooth and continuous operations.
o Example: Cleaned and calibrated pressure gauges and thermometers
used in pasteurization processes.
 Cleaning-In-Place (CIP) systems: Understood the process of automated
cleaning of machinery, ensuring hygiene without disassembly.
o Example: Observed the chemical cycles and temperature settings for
CIP systems used in pipelines and tanks.

4. Insights into Logistics and Supply Chain Management

 Coordination of milk distribution: Learned how milk is transported in

insulated tankers while maintaining freshness.
o Example: Observed route optimization to minimize delivery time
and fuel consumption.
 Challenges in rural logistics: Gained insights into overcoming
transportation issues, such as lack of refrigeration at collection points.
o Example: Suggested using portable cooling units at remote
collection centers to reduce spoilage.

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5. Exposure to Sustainable Practices

 Energy efficiency: Studied methods to reduce energy usage, such as

installing solar panels and using heat recovery systems.
o Example: Assisted in analyzing the plant’s energy consumption
patterns to identify inefficiencies.
 Waste management: Learned how to manage byproducts like whey and
recycle packaging materials.
o Example: Observed the effluent treatment process to clean
wastewater before disposal.

6. Application of Engineering Concepts

 Fluid mechanics: Applied principles to understand milk flow through

pipelines and pumps.
o Example: Calculated flow rates and pressure drops in the system
during milk pasteurization.
 Thermodynamics: Studied heat transfer mechanisms in pasteurizers and
chillers.
o Example: Monitored temperature variations and ensured consistent
heat exchange during processing.

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7. Development of Problem-Solving Skills

 Troubleshooting technical issues: Identified and resolved minor

mechanical problems in machinery under supervision.
o Example: Diagnosed a conveyor belt misalignment issue and
assisted in its correction.
 Critical thinking in operations: Suggested improvements in storage
practices to optimize space and reduce waste.
o Example: Proposed reorganizing warehouse layouts to accommodate
additional packaging materials.

8. Enhanced Teamwork and Communication

 Collaborated with cross-functional teams: Worked closely with

supervisors, lab technicians, and logistics staff to ensure smooth
operations.
o Example: Participated in a team effort to recalibrate sensors in the
packaging line.
 Effective communication: Improved skills in conveying technical
information clearly during discussions and feedback sessions.
o Example: Presented a summary of daily activities and suggestions
during the final review.

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9. Awareness of Market Trends and Consumer Needs

 Consumer demand analysis: Learned about the growing demand for

value-added dairy products like flavored milk and yogurt.
o Example: Assisted in a market study to explore potential product
expansions.
 Packaging innovations: Studied consumer preferences for eco-friendly
and tamper-proof packaging solutions.

10. Professional Growth and Career Insights

 Practical exposure to industry standards: The internship bridged the

gap between theoretical knowledge and industrial applications.
o Example: Applied concepts of mechanical engineering to understand
and optimize plant operations.
 Career motivation: The training reinforced my interest in mechanical
engineering, particularly in food processing and automation.
o Example: Gained clarity on pursuing a career in industrial
engineering with a focus on sustainable practices.

11. Sustainability and Environmental Awareness

 Eco-friendly initiatives: Observed efforts to reduce carbon footprints

through renewable energy and efficient resource utilization.

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 o Example: Participated in discussions on implementing biogas
systems to power boilers.
 Waste reduction: Understood the importance of reducing and recycling
dairy byproducts to align with environmental regulations.

12. Understanding Workplace Safety Protocols

 Safety in operations: Learned how to operate machinery safely and the

importance of wearing protective gear in industrial environments.
o Example: Adhered to protocols for handling chemicals during CIP
processes.
 Emergency response readiness: Understood procedures for equipment
failure and accident prevention.
o Example: Participated in a mock drill for handling power outages
during milk processing.

13. Strategic Thinking and Process Optimization

 Process improvements: Identified areas for efficiency enhancements in

operations, such as reducing bottlenecks in the packaging line.
o Example: Suggested adjustments to the conveyor belt speed to
synchronize with sealing machines.

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14. Knowledge of Cost Management

 Operational cost control: Gained insights into how the cooperative

minimizes production costs without compromising quality.
o Example: Learned about bulk purchasing of raw materials to reduce
procurement expenses.
 Resource allocation: Observed how budgets are allocated across
departments for optimal utilization.

15. Leadership and Management Skills

 Supervisory insights: Learned how supervisors manage daily operations

and coordinate with multiple teams.
o Example: Shadowed a shift manager to understand task delegation
and time management.
 Problem escalation: Learned when and how to escalate issues to higher
authorities for resolution.

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5. CONCLUSION:

The internship has provided me with a valuable opportunity to gain hands-on

experience in understanding management challenges. It has been an essential
part of grasping the full process and procedure of various functions within the
organization. Through this training, I have been able to differentiate between
the theoretical concepts and their practical application, particularly in areas like
account management and inventory control. This experience is shaping up to be
instrumental for my career. I've also realized that an organization's ability to
stay competitive and produce efficiently heavily relies on the motivation and
attitude of its workforce. Additionally, I’ve gained practical knowledge of how
different departments within the organization function.

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6. TRAINING CERTIFICATE:

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