EXPERIMENT 17 VISIT TO DAIRY PRODUCT MANUFACTURING PLANT

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1 Practica Manua EXPERIMENT 17 VISIT TO DAIRY PRODUCT MANUFACTURING PLANT Structure 17.1 Introduction 17.2 Objective 17.3 Experiment Procedure 17.1 INTRODUCTION Dairy pants engaged in the manufacture of severa products are known as dairy products factory. The product mix is decided by the entrepreneur depending upon severa factors ike avaiabe faciities in the factory, avaiabiity of the raw materias, technica know-how, competence of the workers, market demands, profitabiity etc. before starting the production. In this exercise the students wi observe manufacturing processes for various products and the faciities required for them in a dairy pant. They wi aso earn the marketing requirements for various products OBJECTIVE To get famiiar with the various activities of a dairy product manufacturing pant 17.3 EXPERIMENT 1. Procedure Visit a dairy product factory. Observe and record the foowing observations Name of dairy pant Location Tota area Type of organization: Govt / Pubic sector / Co-operative / Private sector Date of commissioning Capacity of the pant Equipments avaiabe in the pant Name 56 Type

2 Make Capacity Visit of Dairy Product Manufacturing Pant Various sections in the pant Number of personas working in the pant Administrative Technica Supporting Product handing method: Manua/ semi automatic/ automatic Quantity of mik procured Source of mik suppy: Farm/Co-operative/ Private agencies/ Chiing centers/ others Equipments avaiabe at reception dock: Tests carried out to assess the quaity of mik at reception dock: Sensory, chemica and microbia tests. Method of storage of raw mik: Number of storage tanks/sio/overhand tank Capacity: Processing of mik Method of pasteurization: Batch/Continuous Capacity of pasteurization pant: /hr Functioning of Fow diversion Vave: Packaging machines: Make Capacity Other equipments: Homogenizer, bender, vats, baance tank etc. Name of the products manufactured in the pant Cream products: Steriized cream/ Whipped cream/ Pastic cream etc. Quantity of mik separated Yied of cream, %yied Fat % in mik Fat % in cream % recovery of fat in cream Butter / butter spread Quantity of cream used Yied, %yied Fat % in cream Fat % in butter % recovery of fat in butter 57

3 Practica Manua Ghee Quantity of cream/butter used Yied, %yied Fat % in cream/ butter % recovery of fat in ghee - Cheese Type of cheese manufactured - Quantity of mik used Fat: Casein ratio in mik % Yied of cheese Ripening room temperature C Processed cheese/cheese spread Type of cheese used Proportion of different cheese used for processing Name of the emusifier Quantity Rate % Coour Quantity Rate % Name of preservative Quantity Rate % Condensed mik/ Evaporated mik Quantity of mik used: Quantity of condensed mik/evaporated mik made: Type of evaporator used: Method of packaging : Capacity of the evaporator: Ice cream Type: Ingredients used: Quantity manufactured: Method of packaging: Buk/ Retai Hardening room temperature: C Mik powder SMP/WMP/Infant food/ Coffee whitener/ weaning food 58 Quantity of mik used:

4 Quantity of mik powder: Type of drier: Visit of Dairy Product Manufacturing Pant Capacity of the drier: Method of packaging: Other products manufacture: Fermented mik products, Indian dairy products, infant foods, etc. Ceaning procedures: Manua/CIP Quaity contro: Faciities avaiabe Sensory, chemica and Microbia tests foowed to asses the quaity of mik and mik products Tests conducted on quaity of water, detergents and equipments etc. Utiities Observe the foowing Operation of CIP, strength of detergents used, Pumps Refrigeration fow diagram of refrigeration, Number of compressors, refrigerant used, Ice Bank Tank capacity etc. Boier Type of boier, Capacity, Number of boiers, Make, Water softening unit Generator Type, Make, Capacity, Number of generator Effuent treatment pant type, capacity, operation, tests foowed, use of treated water Consumabes- Source of water, eectricity, coa etc. Note: Study guide for the above experiments is Laboratory Manua for Dairy Technoogy Practica pubished by ICAR subcommittee on Dairy education. 59

5 Indira Gandhi Nationa Open University Schoo of Agricuture BPVI-015 Dipoma in Dairy Technoogy (DDT) PRACTICAL MANUAL

6 Indira Gandhi Nationa Open University Schoo of Agricuture BPVI-015 PRACTICAL MANUAL Experiment 1 Preparation of Khoa 5 Experiment 2 Preparation of Guabjamun 8 Experiment 3 Preparation of Peda 12 Experiment 4 Preparation of Burfi 15 Experiment 5 Preparation of Rabri 19 Experiment 6 Preparation of Kaakand and Mik Cake 23 Experiment 7 Preparation of Kheer 27 Experiment 8 Preparation of Chhana 30 Experiment 9 Preparation of Rasogoa 33 Experiment 10 Preparation of Sandesh 36 Experiment 11 Preparation of Rasmaai 39 Experiment 12 Preparation of Channa-Murki 42 Experiment 13 Preparation of Paneer 45 Experiment 14 Study of Vacuum Pan/Doube Effect/Tripe Effect of Evaporator 49 Experiment 15 Study Of manufacture of Spray Dried Mik Powder 51 Experiment 16 Preparation of Vaue Added Products From 53 Experiment 17 Visit of Dairy Product Manufacturing Pant 56

7 Programme Design Committee Prof. H.P. Dikshit Ex-Vice Chanceor IGNOU, New Dehi Prof. S.C. Garg Acting-Vice Chanceor IGNOU, New Dehi Prof. Panjab Singh Vice Chanceor Banaras Hindu University, Banaras (U.P.) Shri A.N.P. Sinha Former Additiona Secretary Ministry of Food Processing Industries Dehi Ministry of Food Processing Industries, New Dehi : Mr. K.K. Maheshwary Mr. R.K. Bansa, Consutant Mr. V.K. Dahiya, Tech. Officer (Mik Products) NDRI, Karna, Haryana : Dr. S. Singh, JD (Academics) Dr. S.P. Agrawaa, Head (Dairy Engg.) Dr. Rajvir Singh, Head (Dairy Eco.) Dr. K.L. Bhatia, Ex-Principa Scientist Dr. S.K. Tomar, Principa Scientist Dr. B.D. Tiwari, Ex. Principa Scientist Dr. Dharam Pa, Principa Scientist Dr. A.A. Pate, Principa Scientist Mother Dairy, Dehi : Dr. P.N. Reddy, Former Quaity Contro Manager Practica Manua Preparation Team Mik Pant, Gwaior : Shri M.E. Khan, Manager - Pant Operation Dehi Mik Scheme, Dehi : Shri Ashok Bansa, DGM CITA, New Dehi : Shri Vijay Sardana Mahaan Protein, Mathura (U.P.) : Dr. Ashwani Kumar Rathor, GM Technica IGNOU, New Dehi (SOA Facuty Members) : Dr. M.K. Saooja, Dy. Director Dr. M.C. Nair, Dy. Director Dr. Indrani Lahiri, Asstt. Director Dr. P.L. Yadav, Sr. Consutant Dr. D.S. Khurdiya, Sr. Consutant Sh. Jaya Raj, Sr. Consutant Sh. Rajesh Singh, Consutant Programme Coordinators : Prof. Panjab Singh, Dr. M.K. Saooja and Dr. P.L. Yadav Writers : Dr. Dharam Pa Editors: Dr. P.L. Yadav, Dr. S.K. Kanwaojia, Dr. B.D. Tiwari, Dr. J.S. Sindhu and Dr. R. Baachandran and Dr. Vani Rai K. Dr. M.K.Saooja Coordinators: Dr. M.K. Saooja, Dr. P.L. Yadav and Dr. J.S. Sindhu Materia Production Mr. Rajiv Girdhar Section Officer (Pubications) Word Processing Mr. Bhim Singh November, 2006 Indira Gandhi Nationa Open University, 2006 ISBN A rights reserved. No part of this work may be reproduced in any form, by mimeograph or any other means, without permission in writing from the Indira Gandhi Nationa Open University. Further information on the Indira Gandhi Nationa Open University courses may be obtained from the university s office at Maidan Garhi, New Dehi Printed and pubished on behaf of the Indira Gandhi Nationa Open University, New Dehi, by Director, Schoo of Agricuture. Laser typeset by : HD Computer Craft, EA 1/75, Inderpuri, New Dehi Paper Used : Agrobased Environment Friendy Printed at :

8 BPVI-015 DAIRY PRODUCTS-II In the theory course we have studied different aspects such as definition, composition, method of manufacturing, factors affecting quaity, packaging, shef ife and storage of heat desiccated products, acid and heat coaguated products and concentrated and dried products. These aspects of Khoa and Chhana based indigenous sweets have aso been covered. This practica course has been designed to undertake the practica exercises for the manufacturing of the above mentioned products. In case of heat desiccated products khoa, Rabri and Basaundi, wi be prepared from mik. In addition to that different khoa based sweets ike peda, burfi, guabjamun, kaakand and mik cake wi be prepared from the khoa. In case of heat and acid coaguated products paneer and chhana wi be prepared and the chhana thus obtained wi be used for the preparation of different chhana based sweets such as rasogua, sandesh, rasmaai and chhana murki. Concentrated mik, dried mik and dairy whitener wi be prepared in a dairy pant or their preparation wi be demonstrated to the students during pant visit. Study Guide The Practica Course invoves 10 counseing sessions (4 hours each) of intense work. During the counseing the guided and unguided experiments wi be performed by the students. The practica evauation sha be done under two components: (i) guided experiments and (ii) unguided experiments. The guided experiments sha be performed during the counseing sessions under the guidance of the counseors. The unguided experiment sha be undertaken by the students in the ast session. For unguided experiments, student sha not be provided any guidance whie performing the experiments(s). Both the components wi be evauated. The weight age of 70 per cent wi be assigned to guided experiments and 30 per cent is for unguided experiments. Each experiment performed by the student woud be evauated. The student performance woud be assessed by the counseors covering various aspects ike manipuative skis, observation and their understanding of the basic concepts reated to experiment. We woud advice you to study the basic concepts given in course mik production and quaity of mik. This wi enabe you get maximum benefit from this practica Course. Laboratory Note Book An important part of you scientific training is the maintenance of a compete and up to date record of your aboratory work. For writing and reporting the experimenta data, notebook of 200 pages is required that is avaiabe in market. You shoud prepare tabes for recording the date as given in the manua. For, each experiment, you shoud write down the type of sampe, tite of the experiments to be conducted, observations and resuts.

9 Practica Manua Genera Precautions for Practicas Wear a ab coat or apron whie performing the experiments. Wash your hands thoroughy with soap and water and then with potassium permanganate soution before handing food. Pan your work carefuy, read recipes and instruction propery. Assembe a required utensis before beginning, weigh or measure ingredients. Do not throw the waste food or any soid in the sinks. Cean the utensis thoroughy and wipe before you eave. Use the cutting board to keep hot utensis, never keep them on poished surface. Read the instruction of operator before use of equipment. Good quaity buffao mik shoud be taken for the manufacturing of khoa and paneer. Good quaity cow mik shoud be taken for the manufacturing of chhana. Row mik for the manufacturing of concentrated and dried mik shoud be of high quaity and shoud not have any deveoped acidity. Specia care is needed for ceaning the equipment/foor. Quaity of products shoud be tasted. Ingredient used shoud be of known quaity and standard. Aways draw a sampe for anayses. Whie visiting the dairy pant making cheese and ice-cream you record a the observation. 64