A basic and useful report.

1. A
Project Reporton Dissertation
in
MOTHER DAIRY
Kolkata
Presented by:
Sukanya Halder
B.Tech/M.tech Dual Degree
Year- 5th
Roll Number - 1060070
KIIT SCHOOL OF BIOTECHNOLOGY

2. ◊ Introduction
◊ Vision and Mission
◊ Milk & Traditional Products
◊ Products Manufactured
◊ Product Specifications & Details
◊ Milk Process
◊ Milk Production System
◊ Manufacturing & Processing
◊ Quality Control
◊ Product Testing in QA Lab
◊ Tests Carried out in QA lab
◊ Test Result & Discussion
◊ Picture Gallery
◊ Bibliography
Presentation Flow

3. Introduction
 MOTHER DAIRY CALCUTTA, a Government of West Bengal project, was started under
Operation Flood II of National Dairy Development Board . It was set up initially to cater to
the demand of the Kolkata urban agglomeration spread over the Kolkata Metropolitan area.
 Mother Dairy is also reaching out to the consumers of other Districts. The commissioning
of the Dairy started in July 1978 and the first Distribution vehicle loaded with milk sachets
rolled out of the Dairy in the morning of 8th December 1978. Initially, the management of
Mother Dairy was looked after by the National Dairy Development Board .
 Mother Dairy safeguards the interest of the rural milk producers by encouraging co-
operative movement & marketing the surplus milk available from the villages, thus helping
the milk producers to realize their own potential for organized endeavour & the creation of
more rural wealth in the shape of 'Anand Pattern' as profounder by Dr. V.Kurian , The Milk
Man of INDIA.
 In November 1996 , the management of Mother Dairy was taken over by West Bengal
Cooperative Milk Producers’ Federation.

4. Vision And Mission
Vision – “Provide quality food and beverages to consumers at
affordable prices while ensuring fair returns to the producers.”
Mission – “Mother Dairy’s heritage is intrinsically linked to the
cooperative movement in India. With determination & pride
we will continue to serve our farmers, rural India & our
consumers. Our values reflect who we are & what we firmly
believe in.”

5. Milk
Conversion of Milk into Traditional
Indian Dairy Products
Cultured PrecipitationCondensed
Shrikhand
Ghee
Lassi
Misti Doi
Rabri
Kheer
Khoa
Paneer
Sandesh
Chhana
Rasgolla
Pantoda
Rasmalai
Barfi Pedha Kalakand Gulabjamun

6. Products Of Mother Dairy
Double Toned Milk
Toned Milk
Cow Milk
Mishti Doi
Probiotic Yogurt
Flavoured Yogurt
Paneer
Cow Ghee
Ice Creams

7. Product Details
Product Milk fat SNF Sugar Protein Carb. Caramel Flavour Energy
(100gm)
Sweet
Yoghurt
3.0 13 18 4.8 7.0 0.2 146 kcal
Probiotic
Yoghurt
3.0 11 4.8 71 kcal
Flavoured
Yoghurt
3.0 13 13 4.8 7.0 Green-
mango
Chocolate
Pineapple
Vanilla
126kcal
Yoghurt
For preparing yoghurt about 11% cultures of each Streptococcus thermopiles and
Lactobacillus bulgaricus is used.

8. Product Details
Specific Details of Types of Milk produced in Mother Dairy Kolkata
Type of milk Minimum fat Min. SNF
Cow Milk 3.5 8.5
Toned Milk 3.0 8.5
Double toned Milk 1.5 9.0
Full Cream Milk 6.0 9.0
Cholesterol free Milk 0.5 8.9
Standardized Milk 4.5 8.5

9. Product Specefications
Cow Milk: Fat-3.5% & SNF-8.5%
Double Toned Milk: Fat-1.5% &
SNF-09%
Toned Milk: Fat-3% &
SNF 8.5%

10. Product Specefications
Sweet Yogurt: Fat-3 % & SNF-13% Probiotic Yogurt: Fat-3 % & SNF-
11%
Flavoured Yogurt: Fat-3 % & SNF-13%

11. Some Other Products :-
Different Flavoured Yogurts
Probiotic Dahi

12. RAW MILK
RECEPTION
HOMOGENISATIONPASTEURIZATION
STANDRADIZATIONCLARIFICATION
PROCESSED MILK DEEP CHILLING DISPATCH
Milk Process

13. Pasteurization
Kills all pathogenic bacteria present in the milk. Thus making it safe for
consumption
Homogenization
Improves palatability of milk
Standardisation
Maintain uniformity by raising or lowering fat and SNF (solid not fat)
percentage to desired levels
Clarification
Milk is spun at very high speed, removing all dust particles
Milk production system

14. Manufacturing of Sweet Yoghurt :-
Milk, powder, water and sugar are added in the vat
It is agitated
It is heated up to 90◦C
It is cooled to 45◦C
Culture and caramel is added
It is packaged
It is stored in incubator room at 43◦C for 4-5 hours
It is then transferred to cold room
It is dispatched
Manufacturing Process

15. Continued..
Manufacturing of probiotic yoghurt :-
Milk, powder and water are added in the vat
It is agitated
It is heated up to 90◦C
It is cooled to 45◦C
Culture is added
It is packaged
It is stored in incubator room at 43◦C for 4-5 hours
It is then transferred to cold room
It is dispatched
In case of probiotic
yoghurt commercial
cultures like DH-111
and YOLP are used

16. Continued..Manufacturing of flavored yoghurt :-
Milk, powder, water and sugar are added in the vat
It is agitated
It is heated up to 90◦C
It is cooled to 45◦C
Culture and flavor l is added
It is packaged
It is stored in incubator room at 43◦C for 4-5 hours
It is then transferred to cold room
It is dispatched
Amount of flavour
added:-
Green mango: 0.5%
Vanilla : 1%
Chocolate : 0.3%
Pineapple : 0.25%

17. Continued..
Manufacturing of mango flavored ghol :-
Curd water, salt and sugar are added in the vat
It is agitated
It is heated up to 90◦C
It is cooled to 10-15◦C
Yoghurt and flavor is added
It is agitated and mixed properly
It is packaged and put in cold room
It is dispatched

18. Milk is heated at 90◦C
It is brought to 86◦C
Citric acid is added
Curdling of milk occurs and it is allowed to settle for 10 minutes
Agitation is given
Paneer water is drained
Paneer is put in hoof bar
It is compressed for 10 minutes at 4-6 kg pressure
It is then put in cold water at 7-8◦C for 2 hours for the paneer to solidify
Processing
Processing of Paneer :-

19. It is put in brine water solution for 1 hour to increase self life
It is kept in cold room overnight
It is cut into pieces(100gm, 250gm, 1kg and 5kg)
It is put into packets
Vacuum packaging is done
It is kept in cold store and is ready to be dispatched
Continued..

20. Milk is tested for adulterations and quality at the time of collection
The temperature is judiciously maintained less than 4°C always
No contamination by human hands takes place, since processes
are automated.
The trucks that deliver milk have specified guidelines
Travel time between collection and distribution points is always
less than 36 hours to ensure milk freshness.
Quality Control

21. Why is Testing Necessary ?
Milk testing and quality control is an essential component of any
milk processing industry whether small, medium or large scale.
Milk being made up of 87% water is prone to adulteration by
unscrupulous middlemen and unfaithful farm workers.
Moreover, its high nutritive value makes it an ideal medium for
the rapid multiplication of bacteria, particularly under unhygienic
production and storage at ambient temperatures.
Product Testing in QA Lab

22. Some Tests Carried out in QA Labs
Organoleptic Evaluation
Check taste and flavor of milk.
COB Test
Conduct COB test by taking about 2 ml milk in a test tube, boil on the flame of a spirit lamp
formation of clots in the test tube indicates COB positive milk and is unacceptable.
Acidity Test
Taking 10 ml milk in 10 ml conical flask. Titrate against N/10 NaOH using phenolphthalein
indicator to check acidity. Acidity above .153% is not acceptable.
Rosalic Acid Test
To 5 ml 60% alcoholic Rosalic acid in a test tube add 2 ml of milk . Rose red color
development indicates neutralizer presence in milk and formation of flakes indicates disturbed
salt balance.

23. Some Tests Carried out in QA Labs
Alcohol Test
Alcohol test is done to know the quality of milk. To 2 ml milk in a test tube add 2 ml 68%
alcohol. The presence of flakes indicates alcohol positive and such milk is rejected. The
alcohol test determines the susceptibility of milk to coagulation due to developed
acidity, salt unbalance or high albumen content.
FAT & SNF
Fat & SNF can be determined using Gerber’s method or using a Milcoscan.
SNF can also be determined using lactometer reading and Fat value and putting the
formula CLR/4 +Fat x .2 + .29
Milkoscan is the latest technology machine for scanning of milk and uses infra red rays
to analyze the milk for
• Fat
• Protein
• Lactose
• SNF

24. Continued…
Tests Carried out in QA Labs
Microbe Test
For testing the presence of microbe, plating method is done. In this process 1ml
of various sample (milk, yoghurt, ghol ,butter and paneer) is collected and its
dilution is prepared. Then it is plated according to the drop plate method. For
paneer 1gm paneer is grinded with sterile phosphate buffer and then its dilution
is prepared. Also for preparing dilutions of other samples sterile phosphate
buffer is used.
For plating two types of media is used :
•Violet Red Bile media- it is used to observe the coliform growth in the sample
•Milk agar media- it is used to determine the total plate count of the sample.

25. Continued…
Tests Carried out in QA Labs
Paneer Test
Appearance -- Shall be clear and free from dirt, surface discoloration and insect's
contamination. It shall not have any free moisture.
Flavour -- It shall have pleasant odour and characteristic mild acid flavour
Texture – It shall have a closely-knit smooth texture and spongy body.
Moisture
2 gm. shredded paneer is weighed in a dish. Mix with 4 ml hot distilled water with glass
rod. Wash off the particles on glass rod using 1 ml water. Mix the contents thoroughly.
Heat the dish at 100 + 2◦ C for 4 hrs. Cool in desiccators. Observe the final weight.
Calculation :
Moisture % = 100 (W1 - W2)
(W1 – W)
W1 = dish + sample before drying
W2 = dish + sample after drying
W = Mass of empty dish

26. Continued…
Tests Carried out in QA Labs
.
Lactometer Test
It is an instrument use to measure the SNF present in milk. In this process the lactometer is
dipped in milk n it shows the reading.
Calculation: SNF= (CLR/4) + .25f+ .44
CLR = Lactometer reading
f = % of fat
Lactometer Test

27. Details about some
Tests carried out in QA Labs
Tests for Free Fatty Acids
It is done to measure the % of Oleic Acid
10 gram ghee is taken
Neutralizer is prepared
Neutralizer are added to the ghee
It is kept at 50°C for 15 minutes with repeated shaking
It is then titrated with 0.1N NaOH

28. Continued..
Protein Test
10 ml Milk + .4ml Saturated potassium oxalate
Keep Undisturbed for 3 minutes
Titrate with NaOH
Then add Formalin solution (2ml)
Titrate with N/10 NaOH

29. Continued..
Acid Value Test for Butter
20 gram Butter + 90ml boiling water
Add Phenolphthalein about 1ml
Titrate it with NaOH
Calculation:2.28*V÷W
W: weight of the sample(20gm)
V: volume of NaOH used
Standard : 0.06 Maximum

30. Continued..
Gerber Test :-
5gm butter /10.75 ml milk is taken and to that 10 ml of Gerber sulfuric acid :( specific gravity
1.823) at 15-21c is added into Gerber Butyrometer
Add 1ml of iso amyl alcohol and insert the lock stopper grasp the test bottle at the graduated
column and shake it until the curd is completely digested.
Adjust temperature of the milk sample to 22-21C°.
Place them in a Gerber centrifuge close the cover and lock. After the required speed of1500
rpm centrifuge for 5 mint, stop the centrifuge.
Standard : 80 to 84%
Milk should be heated at 40°C and then brought to room temperature.

31. Continued..
MBR Test
10 ml Milk + 1ml Methylene Blue.
Put in water bath till the color becomes white.
Standard : If Milk quality is good then it will take 6-7 hours to discolour.
BR Test
Heat Butter till it forms Ghee/Heat ghee at 40◦C
Filter it and remove the residue
Put in Butyro Refractometer and take BR readings
Standard : 40 - 44 %

32. Continued..RM Value
It is done for both butter and ghee. In case of butter it is first heated to high temperature to
convert it into ghee and then the test is performed. It is used to measure the volatile fatty acid
present in the sample.
Standard: 21-28
5 gm. ghee/butter is taken
20gm of 98% glycerol is added
2 ml of 50% NaOH is added
Heated till it is clean
It is kept covered and cooled

33. Continued..
50ml diluted sulfuric acid is mixed
93 ml boiled water is added which was boiled for 15 minutes
3-4 glass balls were added to prevent the flask from blasting and it is heated
Then it is distilled by the process of distillation
Distilled fluid is collected for 1st 20 minutes

34. Continued..
The fluid is kept at 15◦C for 10 minutes
It is mixed and titrated with N/10 NaOH with 1 ml phenolphthalein as indicator
Calculation: Reading – (0.2)*1.1
Blank reading-- 0.2
Ammonia Test
5ml Milk + 1ml Nessler’s Reagent.
Standard : If yellow spot appears at the bottom, then it contains Ammonium Salt.
Test for presence of Urea
Take 2 ml milk in a test tube & add 2 ml DMAB solution and mix the contents.
Standard: Appearance of yellow color indicates the presence of urea making the
milk unacceptable.

35. Continued..
Phosphatase Test
The Phosphatase test is applied to dairy products to determine whether pasteurization was
properly and also to detect the possible addition of raw milk to pasteurized milk.
Pasteurization results in deactivation of Phosphatase enzyme.
1ml of Milk is taken
Substrate is added (5ml)
Put in water bath at 37 ± 1 °C for 2 hours
Standard: If yellow color, then Pasteurization not done properly.
If it is colorless, then Pasteurization done properly.

36. Continued..
Milk Powder Test
Milk powder is dissolved in water
It is centrifuge at 1100 rpm for 5 minutes
The sediment is observed
Standard: The layer of the sediment should not exceed 0.5 cm

37. Continued..
Homogenizing Efficiency Test
Take some milk and dilute it with water
Smear the milk on the slide
Cover it with cover slip
Smear it with cedar wood oil
Observe it under microscope
Standard: The size of the fat globule should not exceed 2 micron

38. Continued..
Salt Test
The salt used in the plant should be free from iodine. So to test this some amount of
freshly prepared starch solution is added to the salt. If blue-black appears then it is
rejected
Chlorine Test
1ml chlorine + 10ml glacial acetic acid + 2gm potassium iodide
Keep in dark for 5 minutes
Titrate it with N/10 Sodium Thiosulphate till it becomes straw yellow
Add 1ml starch
Titrate it with N/10 Sodium Thiosulphate till it becomes colorless
Calculation: Strength of chlorine at ppm= 3546*(1st reading - 2nd reading)
Standard: 40000 minimum

39. Continued..Caustic Strength Test
10 ml Caustic is taken
Add 2-4 drops of Phenolpthelin
Pink Color appears
Titrate with 2.5 Normal Sulphuric Acid until it becomes colourless
Standard: 0.7 to1.5
Specific Gravity Test for Caustic
Cool the caustic till 20◦ C
Immerse the hydrometer
Note the reading on hydrometer
Standard : 1.45

40. Hardness test
Take 10 ml water
Add 4 drops of ammonium buffer solution
Add 3-4 drops of Erichrone Black solution
Titrate it with N/50 EDTA till the color changes from purple to dark green and note the
reading.
pH Test :
It is done with the help of pH meter. Standard is 7-8.
Total Dissolved Solid Test (TDS)
it is done with TDS instrument which gives the reading directly.
The reading varies according to the sample.
Continued..Water Tests

41. Continued..
Milk Polypack Test
Thickness Test: It is done by dial thickness gauge. Standard is 49-50 microns.
Printing Test: Print should not come out on a cello tape when it is stuck and peeled out.
Width Test: The standard value is 323 (± 2) mm
Drop Test: It should be dropped 2m for 500ml and 1m for 1000 ml.
Milk Polypacks

42. Test Result And Discussion
Test Name Result And Discussion
COB TEST (Clot On Boli) Formation of clots in the sample indicates COB positive milk and is
unacceptable.
Generally milk from Midnapur district were sometimes COB
positive.
ACIDITY TEST Acidity above .153% is not acceptable
All milk samples have acidity below the given standard.
ROSALIC ACID TEST Rose red color development indicates neutralizer presence in milk
and formation of flakes indicates disturbed salt balance.
Peach color tends to deepen if caustic (neutralizer) is present
depending on the amount of caustic.
Generally all sample produce light peach color indicating the
presence of little amount of caustic in it, added to increase the self-
life
ALCOHOL TEST The presence of flakes indicates alcohol positive and such milk is
rejected. The alcohol test determines the susceptibility of milk to
coagulation due to developed acidity, salt unbalance or high
albumen content.
Majority of the samples tested were alcohol negative.

43. Test Result And Discussion
Test Name Result And Discussion
FAT & SNF TEST It is done either by Garber method or with the help of Milkoscan
Majority of the time the results were according to the standard, if it
was more or less than the standard then the batch were rejected.
MBRT TEST Milk with MBR time of less than 7 hours is unacceptable.
All the milk samples had MBR time of around 7 hours.
TEST FOR PRESENCE OF UREA Appearance of yellow color indicates the presence of urea making
the milk unacceptable.
Majority of the samples were Ammonia free.
PHOSPHATASE TEST Yellow color determines that pasteurization was not done properly.
Pasteurization results in inactivation of phosphatase enzyme.
All samples appeared colorless i.e. properly pasteurized.
MICROBE TEST Microbes were observed only on plates that were plated by Dahi
samples. Count of around 400 colonies (approx.) was accepted.
More than that were recorded and reported.
Generally all samples gave a colony count below the standard.
MOISTURE TEST FOR PANEER Differences of about 2gm were acceptable before and after drying.
e.g.: BNIL paneer weight around 16.7191 before drying and
14.7160 after drying. Therefore the diff is around 2gm

44. Test Result And Discussion
Test Name Result And Discussion
LACTOMETER TEST Standard for raw milk is around 30.
Generally though it never reached exact 30 but around or more than
28.5 is accepted.
e.g.: once milk from Midnapur was rejected as it was 26.75
TESTS FOR FREE FATTY ACIDS Standard is around or less than 3.0. It is the % of Oleic acid in ghee.
e.g. BLIN ghee has a value of 1.1844
PROTEIN TEST Standard is around 8.5%
Below that the sample is rejected. Ones milk from Haringhata was
rejected due to lower protein content around 6.2%.
ACID VALUE TEST FOR BUTTER Standard is 0.06%
All samples were around the given standard.
GERBER TEST Standard : 80-84%
Once milk pouch from BNIL was rejected as it had Gerber test
value of around 60%
BR TEST (Butyro Refractometer) Standard: 40-45%. Below or above that range that sample was
rejected.
No sample was rejected on the basis of this test.

45. Test Result And Discussion
Test Name Result And Discussion
RM VALUE Standard: 21-28%
No sample were rejected on the basis of this test.
AMMONIA TEST If yellow spot appears at the bottom, then it contains Ammonia.
Generally, rarely ammonia was found in the milk samples.
MILK POWDER TEST The layer of the sediment should not exceed 0.5 cm.
Generally on samples were rejected on the basis of this test.
HOMOGENISING EFFICIENCY
TEST
The size of the fat globule should not exceed 2 micron. It is used to
check the efficiency of homogenizer.
Once the fat globule size exceeded 2 micron due to fault in
homogenizer
SPECIFIC GRAVITY TEST FOR
CAUSTIC
Standard : 1.45
No samples were rejected.
WATER HARDNESS TEST Standard: .5ml
If the volume of EDTA is more than that then the sample is rejected.
Samples were rarely rejected.

46. Test Result And Discussion
Test Name Result And Discussion
WATER pH TEST Standard: 7-8
No samples were rejected
WATER TDS TEST
(Total Dissolved Solid)
Standard: 300(approx.)
No samples were rejected
SALT TEST Appearance of blue black color in the salt indicates the presence of
iodine and the sample is rejected.
No sample is rejected.
CHLORINE TEST Standard : 40000
More the strength better it is as it is used for CIP (Cleaning In
Place). Sample with less than 30000 is rejected and rejection is rare.
MILK POLYPACK TEST Thickness Test: Standard is 49-50 microns.
Printing Test: Print should not come out on a cello tape when it is
stuck and peeled out.
Width Test: The standard value is 323 (± 2) mm
Drop Test: It should be dropped 2m for 500ml and 1m for 1000 ml.
No samples were rejected.

47. Some Photos of Production Department
Dahi Plant Set Up

48. Some Photos of Instruments used in
QA Testing Department
Centrifuge MBRT
Lactometer

49. Some Photos of Instruments used in
QA Testing Department
Milkoscan Attached to Computer

50. Some Photos of Packaging Department
Polypack Packaging And Final
Packaging

51. Mother Dairy, Kolkata is committed to the
protection of environment by Prevention of
Pollution and Continual Improvement
in our processes and systems to
Improve Environmental Performance.
Minimize Waste generation
Conservation of resources
Use of renewable energy
Recycling & re-use
Environment and Safety:
Storage Area

52. o http://en.wikipedia.org/wiki/Mother_Dairy /Calcutta
o http://www.mannventures.com/mother-dairy-kolkata-
division.html
o http://www.motherdairy.com/MotherDairyPages/home.aspx
o http://www.motherdairy.com/MotherDairyPages/branddetailpag
e.aspx.html
o http://www.deccanherald.com/content/224908/mother-dairy-
expand-operations.html
o http://www.hrgms.com/news.html
Bibliography