A report on in plant training in,

Milk Products Production and Supply Scheme, Lainchaur Kathmandu

(23rd Baisakh to 18th Jestha)

D A I R Y D E V E L O P M E N T C O R P O R A T I O N

By:Sabrina Lama and Sajan Palanchoke

Central campus of technology (food technology)Hattisar, dharan

Tribhuwan University

2008

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ACKNOWLEDGEMENTS

I am happy to present this report on in plant training in MPPSS (Milk Products Production and Supply Scheme), Lainchaur. We were as a trainee in MPPSS for 25 days with the basic purpose of fulfilling the partial requirement for the Bachelors Degree of Food Technology. This document is an attempt to give a brief report upon my learning and experience during my training period. I am deeply indebted to employees of MPPSS, Dairy Development Corporation for their immense support and guidance during my training period and in preparing this report. My sincere thanks go to Mr. Ajab lal Yadav (General Manager), Dr Ishwori Prasad Adhikari (Project Manager, MPPSS),Mr. Madhav Prasad Ojha (Asst. Project Manager), Mr Baidhanath Sah (Processing Officer),Mr. Giridhar Bajracharya (Planning and Human Resource development, Chief)Mr Navraj Khadka(administration Cheif), Mr Narayan Prasad Adhikari (Sales Chief),Mr. Subash Pant(Store Chief) and all the staffs of MPPSS (DDC).

I would like to express my gratitude to my respected teacher Mrs. Geeta Bhattarai (Chairperson of Food Instruction Committee, CCT), Mr. Ganga Pd. Kharel (Assistant Dean, CCT and Chairman of Central Department of Food Technology ) and course Instructor Mr. Pushpa Pd Acharya, CCT, Library Staffs CCT and our respected senior Mr Bikram Upadhyaya for their kind cooperation who has helped to make my training and this report a success.I would like to thank all with their direct and indirect support in bringing out this report.

Thank you.

Sajan Palanchoke Sabrina lama

B. Tech 4th yearCentral Campus of Technology

Hattisar, Dharan

Tribhuvan University

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MANAGEMENTOrganization : Dairy Development Corporation (DDC)

Factory name : Milk Products Production and Supply Scheme (MPPSS)

Address : Lekhnath marg, Lainchaur, Kathmandu Nature of Ownership : Corporation

Certification : An ISO 9001:2000 and HACCP Certified

Information from balance sheet and profit and loss accounts (32nd ashad 2063)

Fixed assets : 270,316,397

Capital Investment :41,183,989Operational cost:a) Collection cost : 1,144,708,429b) Processing cost : 284,171,570c) Sales cost : 42,681,441d) Administrative cost : 73,529,349

Capital Investment :41,183,989

Milk and milk products sales:1,536,340,564

Miscellaneous income:16,939,055

Gross income:1,651,528,392

Product rangeIce-cream PaneerYoghurt (plain and special)Cheese (Yak cheese, Kanchan cheese, Processed cheese, Spread cheese)Chocobar

Note: At MPPSS only yoghurt, jeeramahi, ice cream, processed and spread cheeses are produced. Yak cheese and Kanchan cheese are produced at a number of cheese production centers under MPPSS located at different parts of the country. Paneer is produced at Nagarkot Paneer production center. Actually it was started as a buff cheese production center but the production of buff cheese was stopped in the year 2051BS and since then the center has been producing Paneer, rasvari and mozzarella only.

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Contribution of each product in terms of:

a. Product volume (for fiscal year 062/63)Plain yoghurt 12,82,000 Lice-cream 37,000 LPaneer 58,000 Kgcheese 1,69,000 KgSpread cheese 775.8Rasbari 87,000 packetsLalmohan 59,000 packetsJeeramahi 46,000 L

System of requisition, acquisition, recording and regulation of inventories

A requisition form is filled for the requirement of any material by any section. This form is approved by the relevant section chief and is forwarded to the store, which provides goods/material according to the requisition. If the particular requisition is not in store acquisition force is filled and is forwarded to the financial administration section. After this section has checked budget for that particular, the acquisition form is forwarded to the assistant project Manager finally, the financial administration section gives the purchase order the procurement section. Store provides the particular only after it has been entered to the stores account. A trial balance of the different expenditures and costs is made monthly and is provided to the central office for the monthly balance. According to the annual requirements of the principle materials such as skim Mils, Packaging materials and chemicals required for the production are purchased by the central office, DDC through tenders and quotation calls and are provided to the store of each Milk Supply Schemes.

Besides principle materials other materials such as parts, fuel, equipments, some packaging materials etc are produced by the administration of the MPPS directly which are entered in to the store and requisited by the relevant section, The expenses are shown on the trial balance and is forwarded to the central office.

Record of the quantity of milk products is kept on a daily basis. If sufficient inventory of the product is not present, the store in charge informs the production section for timely production. The cheese section records the quantity of cheese received, the production center from which it has been brought, its fat and moisture content. Cheese is brought to the central cheese store from the cheese production centers as much as it is required.

Number of EmployeesTechnical Administrative Total

Officer 7 5 12Non-officer 113 48 161

System of recording and regulation of inventories The records of quantity of Milk Products are kept on daily basis If sufficient inventory of the product is not present, the store in charge informs the production section for timely production, the cheese section records the quantity of cheese received from the production centre from which

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it has been brought, its fat and also the moisture content. Cheese is brought to the central cheese store from the cheese production centre as much is it is required.

Benefits and facilities: Transportation facilities. One litre milk daily for each employee (For permanent employees). One kg. Ghee monthly for each employee (for permanent employees). Yearly uniform allowances. Facility of canteen within the factory premise. Boots and apron for employees along with washing facilities. First aid facility. Dashain expenditure (about one month salary) Life insurance

Visit to a doctor whenever some injury occurs.

BUILDINGLocation and surrounding:The MPSS is located at a busy business centre of Kathmandu city, Lainchour. The area is a business and office area not suitable for the location of a production plant. The plant is in access of roads on its south and west sides.DDC central office is also situated in the plant premisesTotal area : 5 Ropanies of landPlant area : 14360 square feetPlant Layout: Refer Annex 6

Measures against fire, infestations and other hazards: Fire extinguishers are placed at different accessible places within the factory and its

premises. The plant has a good supply of water, which could be used in case of fire. Since the milk flows through metal pipes from its start of processing to the end, there

is no chance of raw material being infested. Stores are also well kept and suitable temperature is always maintained.

The workers are well informed about the potential hazards caused by the corrosive Chemicals like Nitric acid, Caustic soda, Sulphuric acid and their immediate remedy.

High –tension electrical lines and transformers are well segregated with good fencing. For other hazards or minor injuries and accidents, first aid facility is provided with in

the factory and if needed facility of taking to the hospital. The plant is always kept clean so no other hazards can occur. Fan is used in the filling machine to avoid entrance of flies in the milk pouches

during filling.

Security Measures:

Security guards guard the premises 24 hours and high walls fence the area. No one can enter in the factory unless permission is granted.

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MPPSS products supply system

MPPSS has provision of 4 dealers in Katmandu, Lalitpur, Bhaktapur and Pokhara. Also it has 3 selling shops in Katmandu and Patan. It also has 5 distributors in Katmandu and Pokhara. (Fiscal year 063/064).

Water supplyIn MPPSS: Water provided by tankers is only used.

Power Supply

In MPPSS,Three-phase electricity 11,000 KVA supplied is transformed with a 315 KVA step down transformer to 380 V. One diesel engine electricity generator of capacity of 325 KVA is at stand by.

PRODUCTION

YOGHURTMPPSS manufacture two type of yoghurt.1. Plain Yoghurt: Fat not less than 2%, SNF not less than 8%, 2% added sugar2. Special Yoghurt: Fat not less than 5 %, SNF not less than 8%, 4% added sugar

Raw materials and other ingredients1. Standard milk 2. Butter 3. SMP 4. Sugar 5. Starter Culture 6. Lemon yellow color

Manufacturing details:

Milk Reception from KMSS

Testing sample

Pumping to factory

Filtration

Put in batch pasteurization vat

Standardization of milk

Heating to 80oC

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Adding the needed amount of sugar, SMP (In special 4% sugar and 2% SMP and in plain 4% SMP)

Mixing

Homogenization (55-65 oC at 2000Psi)

Heating to 85 oC

Agitation and hold

Cooling to 42-45 oC

Culturing in that temperature(If propagated culture is used 1-1.5%

If DUS culture is used 17.5 Gms per 500 Liters of milk)

Agitate till 10 min

Filling the earthen pot in incubation room or pouches or cup

*Incubation room(42-45 oC for 2.5 to 3 hours, inspection should be done time to time whether the curd is set or

not)

After the yoghurt is set the heater is turned off and the door is opened for 20-25 mins

*Cold storing (Yoghurt is stored in 5-8 oC temperature)

* Critical Control Point

Packing materials and type of container:

Yoghurt is filled into plastic pouches off 0.5 liters of capacity, earthen containers of 1.5 and 2 liters capacity and in plastic cups with lids of 200 ml capacity. 5 liters earthen containers are

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filled only when orders received from customers.

Table: no. of workers regarding the product

Product name Shift time No. of workers per shiftYoghurt 6 am to 1 pm 6Yoghurt 12 am to 7 pm 3Ice Cream 10 am to 5 pm 9Processed + spread Cheese 10 am to 5 pm 2

Total yoghurt production:-2500-3500 Liters per day. .More demand on festive seasons.

Production machinery: refer annex 1

Technical problem with product and process:

1. The earthen containers are not properly cleaned before filling. So it can be a very potential source of contamination and fault in yoghurt.

2. The help of huge pipes fills the earthen containers, which are stacked in Racks. While doing so, lot's of cultured milk is spilled all over and around the container. Thus making the place dirty enriching the risk of contamination.

3. Plastic cups & Liters of Plastic pouches are filled with mugs, which can be good source of contamination.

4. Cold store and incubation room is not enough clean.5. The plastic pouches were leaky often ,which may incur losses in production. during our

training period in 2065/02/03,10 to 15 liters of cultured milk was lost due to leakage problem.

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ICE CREAM

Ice cream may be defined as a frozen dairy product made by suitable blending and processing of cream and other milk products together with sugar and flavor, with or without stabilizer or color, and with the incorporation of air during freezing process.

Raw material and other ingredients1. water 100L2. Butter 27.5 kg3. Stabilizers/Emulsifiers 700gm4. Flavor 350ml

5. Sugar 25kg 6. SMP 21.2kg

Manufacturing details

* Selection and calculation of Ingredients to makeIce cream with 12-14% fat, 11.5% SNF, 13.15% sugar,

Heating of water to 40 oC

Adding required amount of sugar, SMP, stabilizer

Mix by agitator and raise temp up to 60-65 oC

Butter and liquid glucose is added

Mixing and raising the temp to 85 oC

*Holding at 85 oC Upto 30 mins

Sequentially cool by tap water and lower the temperature upto 55-65 oC

Homogenize the mix at 2000 psi at same temperature

Chill by plate chiller

Keep in ageing vat overnight till 12-18 hrs at 4 oC

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Next day the mix is circulated in continuous ice cream freezer and filled in cup, zee cone etc. after gaining required consistency

Immediately the ice cream is taken for hardening and storage at -25 oC deepfreeze cold store in cardboard

* Critical Controls PointsPackaging materials:Ice Cream is packed in 800ml, 100ml, 500ml and 1 lts. plastic cups with Lid and the zee cones off 300 ml capacity.

Products varieties:MPPSS produces icecream of different flavors such as, vanilla, kesar pista, butterscotch,chocolate etc.

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CHEESE CUTTING UNIT

Cheese is the fresh or matured product obtained after coagulation of milk, cream, skimmed or partly skimmed milk, buttermilk or a combination of some or all of these products. Although there are hundreds of cheese varieties with distinct differences in appearance, taste and flavor, almost all of them are processed in five basic stages.

Preparation of the milk Coagulation of the milk with acid or enzymes Separation of whey to obtain curd Processing of the curd Ripening of the Cheese

DDC Produces three type of Cheese Yak Cheese Kanchan Cheese Mozzarella Cheese

Prior to 2051 B.S Buff cheese was also produced. But Buff – Cheese production has stopped since then due to low market appeal and other reasons.

Cheese cutting unit

Cheese cutting unit is department under MPPSS in which the cheese collected and stored from different cheese producing units all over the nation running under MPPSS, are cut to desired sizes and weights and packed.

The partially spoilt cheese are brought back to the cutting unit and trimmed and repacked for sale.

Notes while working in cheese cutting unit:

Cheese cakes are to be cleaned properly by hand scrapers

The sixes are to be cut according to the demand and packed in plastic vacuum packed and packed in cardboard and submitted to store

Knife, steel table must be cleaned by chlorine water

Cutting employee must wear glove, mask, cap

The cutting room must be routinely cleaned

Packaging materials used in cutting unit:

For cheese- 100gm,0.5kg and 200 gm plastic pouches

For processed cheese- same for cheese(200gm)

For mozzarella cheese-same for cheese(500gm and 1kg)

For spread cheese- 100 gm plastic cup

For paneer- same as for cheese(200gm,500gm,1kg)Table:

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Cheese Production CentersCheese Type District Cheese Production CentreYak

Kanchan

RamechhapDolkhaDolkhaSolukhumbhuRasuwaRasuwa

IllamIllamIllamPanchthar

ThodungChordhungChankhuPikeLangtangGosaikunda

PashupatinagarRaksheJaubareRanke

These produced at different cheese production centers is brought to the Central Cheese Store at MPPSS, Lainchour in Vans, stored there for ageing , cut & dispatched.

Notes:

During summer season, saltpeter is added to the cheese milk (20 g per 100 lit milk) to inhibit the growth if coliforms & other harmful bacteria.

25 –30 % of whey is drained off before cooking cheese so as to increase fuel efficiency. Also, as cooking should not be done for more than 30mins, it would be better to separate some of the whey.

The whey is centrifuged to separate cream before draining.

The processed described is the method followed at Pashupatinagar Cheese Production Centre Illam. Some time temperature combination may differ upon the condition and location of the center.

Technical Problems as associated with product and process:

The raw milk brought for cheese making is not undergone to test its quality. Raw milk is accepted/rejected on the basis o its sensory characteristics

The cheese milk is not standardized properly. Raw milk and skimmed milk was mixed according to the every day experience of the operators.

Milk is standardized to a definite fat content rather than a definite fat: casein ratio, hence the composition of cheese is variable.

There is no proper incubator and refrigerator, so the culture may develop high acidity during incubation. Also the actual volume of culture required could not be produce due to lack of this facilities.

The refrigeration unit of cheese store is not in working condition.

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PROCESSED CHEESE

Processed cheese may be defined as a modified form of natural cheese prepared with the aid of heat, by comminuting and blending one or more lots of cheese, except certain types such as cream, cottage cheese, etc., with water, salt, colour and emulsifier into a homogenous plastic mass (which is usually packed while hot).Processed Cheese manufactured by MPPSS contain 50 % TS, 50 % FDM, & pH of 5.6.

Raw material and other ingredients:Hard Cheese, Butter, Salt, Emulsifiers and stabilizers (Disodium hydrogen orthophosphate and Trisodium Citrate), Water

Recipie for 15-18 kg of processed cheese

Trisodium citrate: 0.05 kgSalt: 0.07 kgDisodium hydrogen orthophosphate: 0.36 kgButter: 0.5kgWater: hard-4.5liter : Soft-3 liter

ManufacturingCheese

Sorting and trimming

Size reduction by expeller

Grinding to fine size by roller size reducer

*Cooking in Vacuum cheese melting kettle at till 85 oC(Pressure up to 1 bar (Pressure should not exceed 1 bar))

Moulding

Cooling for 12hr and setting

Cutting at appropriate size

Vacuum packing in polythene sachets

Cold store (10 oC)

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* Critical Control Point Note: According to Danish process, the above ingredient must be used for 8.5kg green cheese

Sachets size: 200 gm

Production capacity: 15 – 18 kg per/batch

Actual Production: As per demand

Number of workers: 4

Number of Shift & working hours: 1 shift; 10 am to 5 pm.

Technical problem- The hard cheese used for the production of processed cheese doesn't have good quality. It

is either mold infested, very old or those that cannot be sold for some reason.- The stirrer of the vacuum cooker is very difficult to move during initial stages of cooking- The final product is with high moisture content so it is very sticky to hands while

inserting into the packing pouches manually.

SPREAD CHEESE

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Cheese : 10 kgSMP : 1 kgTable butter : 500 gmDisodium-hydrogen orthophosphate anhydrous: 0.325 gmTrisodium Citrate : 0.047 gmGelatin purified : 0.047 gmSalt : 0.04 gmSorbic acid : 0.033 gmColour used: Annato color, which is fat-soluble colour.

Manufacturing

Computation of Ingredients

Mix above ingredients in Cheese spread cooking machine

*Mixed thoroughly till temperature raises to 93 o C

Homogenizing for 3- 4 Cycle (in 1000 Psi)

Bring the mix and stir the bucket of Cheese spread in Ice cubes for more than 1 hrs till 4 to 6 o C

Filling in Cups

Dispatch for store and market (4 o C)

*critical point

Computation of ingredients Water 31.5/55 x cheese SMP 6.5/55 x cheese Butter 3/55 x cheese Salt 0.75/55 x cheese Gelatin 0.3/55 x cheese Sorbic acid 0.2/55 x cheese Disodium hydrogen orthophosphate 2/55 x cheese Trisodium citrate 0.3/55 x cheese Color (yellow) 10gm

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Packing MaterialCheese Spread is packed in 100 ml plastic Cup with Lid.

Technical problems The product during homogenization was spilled due to manual handling of the material,

the problem can be minimized by adopting close system of continuous production.

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JEERA-MAHI

Manufacture

Water is heated up to 40-45 oC

SMP addition (6.3%)

Stirring

Butter addition

Pasteurization (85 oC for 0.5 hour)

Cool to about 40 oC

Culture addition (35gms per 1000L)

Leave 3.5 hours at temperature 35-40 oC

Addition of salt and 2% cumin powder

Store Room

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CHOCOBAR ICE-CREAM

Manufacture

Readymade Ice Cream mix frozen up to semisolid consistency in batch freezer.

The so made ice cream is poured into clean choco key and carefully choco stick is put

This assembly is dipped in the brine -15oC brine solution for 5-10 min

The ice-cream with stick is pulled out from chocokey and put in deep freeze overnight

The next day such ice cream with stick is dipped in readymade chocopost with chocolate syrup

Chocobar is ready, which is packed in a wrapper and stored to -25 oC deep freeze

marketing

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QUALITY CONTROLRaw material Supplier

Milk Butter, Cream : KMSS

SMP : BMSS, and global tender (karnal milk foods ltd, karnal, India)

Sugar : Tender (Salt Trading Corporation Ltd – STCL)

Yoghurt/Cheese Cultures : Chr. Hansen's Lab, Denmark

Gelatin, flavor, and color : Tenders and quotations (international flavors and fragrances India limited, Chennai) (Duckworth flavors India pvt, ltd, Banglore)

Regular or Occasional suppliers:

KMSS, BMSS, STCL, Chr. Hansen's Lab are regular suppliers while others are occasional supplier.

Inline Quality ControlYoghurt Production Line

Pasteurization temperature and time, amount of ingredients, amount and temperature of starter culture addition, temperature of incubation, cleaning and sanitizing of the equipments.

Ice Cream Production line

Formulation of Ice-cream mix, pasteurization time and temperature of ageing mix, temperature of freezing, overrun control, cleaning and sanitizing equipments.

Processed Cheese production line

Temperature and time of processing, amount of ingredients, weight of packages.

Cheese Stores, cutting and packing line

Wiping the cheese with water and over turning cheesecakes each day, cleaning the cheese stores, weight of packages.

Lab Quality Control

- The entire chemical, physical and microbial tests are performed in the laboratory.

- Compliance with the standards are checked and informed to the processing section necessary corrective measures are suggested.

- The microbiology lab used to control starter culture propagation but nowadays ready made freeze dried pure cultures are used..

- Records of the results are kept which can be used to take corrective action if needed.

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Tests on finished Products

Yoghurt : Sensory, acidity, pH, TS, fat, weight of packet, coliforms count, yeast and mold count.

Ice cream : Sensory, overrun, fat, TS, coliforms count, weight of packet.

Ghee : Sensory, FFA, moisture, adulterations.

Paneer : Sensory, acidity, fat, TS, moisture

Cheese : Sensory, moisture, FDM, WFFC, salt, pH, acidity yeast and mold count.

Tests on packaging material

Different tests as per specification given by DDC are performed.

STORAGEStorage Condition of raw materials

- Butter storage at –15 to -25o C

- SMP, Sugar, Flavor, Color, etc are stored at ambient condition

- Cheese stored in four-cheese store about (10 oC) with separate refrigeration unit.

Yoghurt store:

One refrigerated and insulated cold room of 5000 lts yoghurt storing capacity with wooden racks. Temperature maintained between 5-10 oC. R.H not maintained.

Ice cream store:

One Ice cream freezer store of capacity 2000 lts ice cream. Temperature maintained at -15o C to -

25 o C. R.H not maintained.

Cheese Store:

There are 4 cheese stores. The combined capacity of cheese store is 20000kg. Temperature is maintained below 10o

C. R.H not maintained.

Butter Store:

Butter is stored in the same freezer room as ice cream is stored.

Style of stacking the finished products:

Yoghurt: Butter: Cheese: Ghee:

Ice cream:

Storing in wooden racks.

Stacking one block over others.

Stacking in wooden racks.

Stacking container and cartoon one over other.

Stacking crater containing the ice cream cups one over other.

Measure taken against storage hazards and losses

-The stores are locked and the keys remain with the storage in charge only.

-Washing of Paneer with clean water and wiping of cheese with salt water for protection against yeast and molds.

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Average storage period of finished product before dispatched

Yoghurt Ice cream Paneer

Ghee

CheeseProcessed Cheese Cheese spread Chocobar

: 1-2 days: 2 days to 1-2 month : 2-3 days: 1-8 weeks: 15 days to 6 months : 1-7 days: 1to 2 days: 1to 2 days: 1 to 2 days: 1-2days: 1-2days

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Specific storage problem- Cheese store are not kept well cleaned and so there is problem of mold growth in

cheese store.- No systematic and neat staking of product and materials in the store.

MARKETING

MPPSS deals with marketing of all the milk products produced by MPPSS and butter, ice cream, yoghurt, ghee etc produced by KMSS. MPPSS sells its product through four retails outlets-one at Lainchour, one at Basantapur (New-road), Patan and one inside Singh Durgar. MPPSS also supplies products directly to dealers who then distribute the product in the markets. Special order of large quantity can be directly bought from the factory. Cheese is supplied to other MSS and marketed by those supply schemes.

Table: Price list of milk ProductsS.No Milk Products Unit Total dealer

price (Rs)Total Retailprice (Rs)

Total consumerprice (Rs)

1 Yak Cheese" "

1 kg500 gm 146.5

300150

310155

" " 200 gm 61.60 264" " 100 gm 33.80 35

2 Kanchan Cheese 1 kg 290" " 500 gm 139 141 145" " 200 gm 57.60 58.40 60

3 Ice cream ½ liter - - -1 liter - - -2 liters - - -

4 Butter 250 gm 58.75 55.31 60100 gm 25 25.50 27

5 Butta-Ghee ½ kg 125 127 130" " 1 kg 240 244 250

Poly Ghee ½ kg & 1 kg 120 & 235 122 & 239 125 & 2456 Yoghurt – Special

Yoghurt – ordinary1 liter1 liter

37 38 40

Cup – Yoghurt 200 ml 10.50 11 127 Fresh Cream 1 liter 120 123 130

" " 500 ml 60 61.50 658 Cheese Spread 100 ml 30 30 359 Mozzarrella Cheese 500 gm 99 99 105

" " 200 gm 41 41 4410 Paneer 1kg - 210 220

" 500 gm 102.5 105 115" 200 gm 45 46 50

11 Processed Cheese 200 gm 57.60 58.40 60

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S.No Milk Products Unit Total dealerprice (Rs)

Total Retailprice (Rs)

Total consumerprice (Rs)

12 Yak Ghee" "

1 litre½ liter

250130

255132.50

270140

13 Peda"

500 gm200 gm

-53 53

14060

14 Rasbari 1 packet 53 53 6015 Lalmohan 1 packet 53 53 6016 Balushahi 1 packet 53 53 6017 Lady cany 1 Packet 53 53 6018 Gudpak 200 gm - - 36

Water

Source : Underground bored water; deep tube well 250 m deep.

Tests : MPPSS doesn't do any test of water.

Pretreatments : MPPSS doesn't undergo any pretreatments.

Volume usage of water: approximate 70,000 liters per day.

Plan Sanitation:

In dairies as in all the food producing and processing firms, absolute cleanliness is vital. Because of their versatile composition, milk and milk products are excellent media for microorganisms. So microorganisms may develop if proper cleaning is not achieved. For cleaning of all dairy equipments, Cleaning in process (CIP) program is used. CIP means circulation of rinsing water and cleaning solutions through machines and other items of equipment interconnected to form a cleaning circuit. The passage of high velocity flow of liquids over the surfaces of equipment generates a mechanical scoring effect, which dislodges deposits of dirt.

CIP Programs for Pipes and Tanks

CIP ProgramCirculation/Washing time (min)

Pipes Tanks1. Pre-wash, cold water 3 52. Lye wash, 1% solution 70oC 12 153. Intermediate wash, cold water 4 54. Acid wash, 0.8 % solution 65 oC 6 105. After wash, water, 85 oC 5 8

Total washing time 30 43

CIP Programs for Homogenizer CIP Program Circulation/Washing time (min)

1. Pre-wash, cold water 102. Lye wash, 1.5% solution 70oC 303. Intermediate wash, cold water 104. Acid wash, 1.2 % solution 65 oC 205. After wash, water, 85 oC 10

Total washing time 80

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Manual cleaning

- Some equipments which could be dismantled and cleaned manually are done so once in a month or once in every two months using water jets and soft non-metal brushes.

- Floors and walls of the processing area are continuously flushed with plenty of warm/cold water.

- Equipments are periodically scrubbed with brushes and rinsed with warm water.

Crate washing

- Plastic crate for yoghurt packet filling are dipped in boiling caustic water solution and scrubbed with hand and rinsed in hot water.

- Crates are cleaned manually be scrubbing also.

Frequency of cleaning

Vats are cleaned with caustic solution and water every time they are emptied. homogenizer, and relative pipelines are cleaned frequently (4-5 times a day). Whole processing plant, pipelines are cleaned twice daily – once before start of operation and then after completion of all operation for the day. Filling machines are only steam cleaned.

- yoghurt pouch crates are cleaned every day after they are returned.

Cleaning Chemicals

- Caustic soda NaOH, Nitric acid HNO3, detergent powders and liquids.- No chlorine containing detergents should be used on account of their corrosiveness. If however

they are used the temperature should never exceed 250C.

Following tasks were performed

Problems observed by trainee regarding Cleaning and Sanitation:

Plant 1. Rough and broken floor and water holding surface making plant dirty.2. Dust falling from ceilings, damp walls, leakage of water from pipes, walls and ceilings,

broken plasters of walls and ceilings.3. Fly trappers are only few4. Dirts on glass window panes, broken glasses5. waste material collected in dead corners of rooms and insufficient dust bins6. Improper placement of unused machineries. 7. Insufficient use of cover in open pipe ends8. Rusted and Uncovered steam pipes (plastics are used for covering)9. Insufficient Ventilation system within plant area10. problem of spiders, cockroaches and rats11. Water condensing from rusted steam pipeline over the packaging rail.12. walls needed to be repainted (Packaging rail)13. Batch no stamping not done in all heads14. Improper placement of Chemicals (Open bags).

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Cleaning procedures: CIP and other general cleaning procedures .Cleaning appliances:

A portable CIP unit consisting of a 500 liters lye boiling vat, a pump and a necessary service pipes and valve fittings

CIP is done following batch process Water losses for flushing water. Other usual cleaning appliances.

Waste and By – Products

By – product process and utilizations:No by – product is utilized at MPPSS. At cheese production center, the by- product cream is churned into butter.

Disposal of waste:Liquid waste goes directly into the municipal drain without any treatment. Solid wastes are collected in a municipal container within the factory premises, which is later, disposed.

Waste water treatment: It is not done.

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OUTSTATION VISIT: NAGARKOT

During our stay at MPPSS we had an opportunity to go for a field visit at Nagarkot. Name of Factory: Cheese and Paneer Production CenterUnder Cheese and Paneer Production Center Paneer, Mozzarella Cheese and Rasbari is manufactured.Milk collectionMilk is collected from various co operatives in the vicinity of kavre district such as,

1) rohini cooperative, raniban2) mahakali cooperative,bhimsensthan3) sanakisan cooperative,janasewa4) krishakhit cooperative,setidevi5) sallebash cooperative, halde

4000liters of milk is collected in flush season whereas 1800liters in dry season.

Production raterasbari- avg.500 packs per daypaneer-400 kg per dayMozzarella-80kg per day

No of manpowerTotal-17Permanent-12Temporary-5

Product sales-wholesale and retailNo product return after sale.

PANEER

Paneer refers to milk solids obtained by the acid coagulation of boiled, hot, whole milk and subsequent drainage of whey. The acids commonly used are lactic or citric acid in both natural and chemical forms.

Raw material and other ingredients1. Whole milk (min 5% fat, 8% SNF)2. Citric acid

Manufacturing details:Whole milk (FAT, SNF ,COB and alcohol tests)

Filtering through Muslin Cloth

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Receiving Tanks

*Pasteurization (85oC for 0.5 hour)

Coagulation with whey or 2% Warm Citric acid Solution (10% v/v of milk)

Leave for 0.5 hour

Straining

Moulding for 1 hr

Dipping in salt solution for 8 hrs

Overnight in cold open air

Cutting and packaging

Note: The Paneer Production Center supplies Paneer in the form of cakes, which is cut and packed at MPPSS.

Packaging MaterialPaneer is packed in polythene sachets. It is packed in weight to 200g, 500g and 1 kg.

Production Capacity180 – 190 Kg Paneer per batch (1000 lts. of milk)

Technical ProblemsThe milk is not standardized prior to coagulating hence leading to Paneer of variable composition.

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RASBARI:

For the Production of Rasbari one should understand from the Channa manufacture.

Flow diagram for Channa Manufacture from Cow Milk

Standardize

Pump

Milk heating vat

*Milk heated to 90 o C

Cooled to 70 –80 o C

Addition of Citric acid or previously collected whey.

Separation of Curd and whey

Holding Coagulation mask in whey for 30 min

Filtration through Muslin cloth (Straining whey)

Cooling the mask in Tap water for 15 –20 min

Dripping whey

Channa

Mixing and kneading into dough in working table

Formed into balls (8-10 gms) using both hands Balls cooked in Sugar syrup for 25 minutes

Texture stabilization in hot water or 5 –10 minute

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and then transferred to sugar syrup 60 o Brix.

Dip puffed balls in 40-50 o Brix.

Cool to 10 o C

Packaging

Storage

Marketing

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MOZZARELLA CHEESE

Manufacture

Milk(fat 3.5%)

Clarification or filtration by musulin cloth

*Heating upto 45oC in cheese vat

Cool to 37 oC

Add culture (yoghurt)At the rate of 3-4 litre yoghurt for 600liter milk

Leave for 0.5 hour

Add rennet (1 spoon of rennet for 100 liter of milk)

Leave for 30 mins

Use cheese harp to cut cheese clot

*Heat to 42-45 oC

Cover till 5 minutes

Inverting the coagulants

Cover for 15 minutes

30

Repeat for 6-7 times

Knead with hot water at 85 oCMoulding for 8-10hrs

Dipping in salt solution (22%) for 24 hours on each side (i.e. total 48 hrs)

Rennet powder:Composition: 50%chymosin 50% pepsin NaclRate 2.5-6gms per 100liter milk

Procedure:Dissolve the powdeeer thoroughly into 10-20 times the wt of cold clean wateer with neutral pH. Add it into the cheese milk and stir it until completely disperse.

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Food Safety Management of DDC by applying HACCP Principles

HACCP and its underlying Principles:

The acronym HACCP, which stands for Hazard Analysis and Critical Control Point, is one which evokes'food safety'. Originally developed to ensure microbiological safety of foodstuffs, HACCP has been broadened to include chemical and physical hazards in foods. The recent growing worldwide concern about food safety by public health authorities, consumers and other concerned parties, and the continuous reports of food borne outbreaks have been a major impetus in the application of the HACCP system

HACCP is a system adopted by the Codex Alimentarius Commission, involving the systematic identification and assessment of hazards and the measures for their control to ensure the safety of food. It focuses on prevention rather than end product testing. A HACCP Plan applies directly to food manufacturing processes and the principles must be used in the development of all new product safety programs.

The HACCP system is a scientific, rational and systematic approach to identification, assessment and control of hazards during production, processing, manufacturing, preparation and use of food to ensure that food is safe when consumed (i.e. it does not present an unacceptable risk to health). With the HACCP system, food safety control is integrated into the design of the process rather than the present ineffective system of end-product testing. Therefore, the HACCP system provides a preventive and thus a cost-effective approach to food safety. The system can be applied throughout the food chain, from the primary producer to final consumer. Its implementation should be guided by scientific evidence of risks to human health. The successful application of HACCP requires the full commitment and involvement of management and the workforce. It also requires a multidisciplinary approach. This multidisciplinary approach should include, when appropriate, expertise in agronomy, veterinary science/medicine, production, microbiology, public health, food technology, environmental health, chemistry, and engineering, according to the particular study.

PRINCIPLES OF THE HACCP SYSTEM

The HACCP system consists of the following seven principles:

PRINCIPLE 1

Conduct a hazard analysis.

PRINCIPLE 2

Determine the Critical Control Points (CCPs).

PRINCIPLE 3

Establish critical limit(s).

PRINCIPLE 4

Establish a system to monitor control of the CCP.

PRINCIPLE 5

Establish the corrective action to be taken when monitoring indicates that a particular CCP is not under

control. PRINCIPLE 6

Establish procedures for verification to confirm that the HACCP system is working effectively.

PRINCIPLE 7

Establish documentation concerning all procedures and records appropriate to these principles and their application.

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DIAGRAM 1. LOGIC SEQUENCE FOR THE APPLICATION OF HACCP

DIAGRAM 2. EXAMPLE OF DECISION TREE TO IDENTIFY CCPS

(Questions to be answered in sequence)

DIAGRAM 3. EXAMPLE OF A HACCP WORKSHEET

These are the basic essentials of HACCP System which every food manufacturing company should follow and so is DDC committed for the successful implementation of this HACCP system via quality management system.

So far HACCP implementation is concerned, DDC is now able to implement only in two of its schemes: KMSS Balaju and MPPSS Lainchaur.

In KMSS HACCP is being followed in every product it manufactures namely Milk (Standard and whole), Butter, Cream and Ghee where as in MPPSS Lainchaur it is implemented only in two of its products i.e. ice cream and Yoghurt.

DDC’S commitment and Food Safety Policy towards consumer: (KMSS)

“DDC shall be conducted on the principle that all consumers are entitled to safe, hygienic and wholesome standard milk and milk product (Ghee and Table Butter) and to protection from unfair trade practice which:

- Has it in or upon it any substance in an amount which leads to health hazards: or- Is sold, prepared, packaged, stored or transported for sale under sanitized and hygienic

conditions - Is labeled, or presented in manner following HACCP Principles”

The required HACCP plan is made as per the given logic sequence given above in Diagram 1.

Here’s an example of the complete HACCP plan of pasteurized milk (From the kind permission of KMSS)

Similarly the HACCP plan of other product of KMSS and that of MPPSS is same as the HACCP plan for milk so far.

SUMMARY AND CONCLUSIONDairy Development Corporation is the pioneer in dairy in Nepal. Dairy Development Corporation is the pride of the nation and the country's largest producer and supplier of milk and milk products. DDC – was established for the economic development or the poor rural farmers so that they can be provided a guaranteed market for milk with fair price.

As KMSS is only the milk supply scheme, which is running in profit under DDC, a lot can be done to run it more profitably. As known the quality of the product of raw milk directly depends on the processing cost i.e. – the good the raw milk quality, lesser the processing cost. But a lot of effort is yet to put for the upliftment of the raw milk, which starts.For the upgrading of the raw milk quality

- Quality improvement training and awareness program should be conducted regularly.

- A stricter implementation of milk inspection, its quality specification, and adulteration tests is required.

- A differential pricing system for high and low quality raw milk can have two positive effects on the upgrading of the raw milk quality.

- Sizeable increase in milk production has forced DDC to utilize milk in best possible ways and in recent times, massive diversification of dairy products not only has benefited the urban consumers but also for the economic development of the rural mass milk producers.

CONCLUSION:Dairy Development Corporation has been striving to improve the quality of life of rural milk producers by developing and organizing the milk collection systems. All these years DDC has provided the Nepalese farmers a place in the sun by creating an assured market for their product. Today, thousands of farmers have organized themselves into hundreds of milk cooperatives, handling among themselves lakhs of liters of milk everyday.With the increase in milk production, DDC has launched a massive program for product diversification in order to serve the urban consumers better with locally produced dairy products. Diversification of milk products and development of positive work culture amongst the

employees, has transformed DDC into a profit making public sector enterprises.

RECOMMENDATIONS: Milk is the quickest means for earning money for the farmers, so if the differential pricing

system is adopted for high and low quality raw milk they put an effort to upgrade the raw milk quality.

Also R.M improvement trainings would be fruitful to produce good quality raw milk for farmers as well as DDC.

It was seen during the field visit in Chilling centre the milk brought by the farmers werevery dirty. So strict rules must be practiced by DDC regarding the receiving of the milk

DDC also needs to undergo innovative research and study to expand newer product rangeand market.

Previously, DDC had only two flavors in ice cream as Viz - strawberry and Vanilla. With the span of 2 yrs DDC launched 14 new flavors which itself was a new achievement for DDC.

DDC should produce newer products like Baby food powder and fruit yoghurts. DDC should open more retail outlets and showrooms in the main cities and try to sell more

of its products. The factory and plant premises were found to be quite disorganized at MPPSS. Also, the

earthen containers for yoghurt filling were found to be placed in unwell manner. More concern must be given regarding the maintenance of plant sanitation and hygiene No any waste treatments were found to be done by both KMSS and MPSS. Thus, it was

highly felt for the quick operation of waste disposal plant. Much has to be done for the upliftment of dairy sector in Nepal. It should start correct

policy making from the top management. Increase in products and processing capacity and expanding it's product range, thereby

increasing it's sales will help solve the problem of “Milk holiday" which has been an important matter of debate.

The weight of the Pouch Milk usually crosses the average weight that is (500 ml). So care must be provided that the milk is packed at the desire weight.

Annex 1

Production Machinery at MPPSS

1) Yoghurt Production Machinery0104 Insulated Tank 1 1000 l VM Tarm0106 Centrifugal pump 1 5000 l/h APV Rosista0601,0602 Batch Pasteurizer 2 1000 l VM Tarm & APC Rosista0603 Centrifugal Pump 1 P & S0604 Yoghurt dosing run 1 Catabriga0606 Starter Incubator 1 2*30+5 l APV Pasilac0609 Boiling vat 1 300 l P & S0704 Homogenizer 1 1000 l/h Rannie

0715 Batch Pasteurizer 1 600 l Valcan Laval

2) Ice cream Production Machinery0701,0702 Batch Pasteurizer 2 320 l P & S0703 Centrifugal pump 1 1000 l/h P & S0704 Homogenizer 1 1000 l/h Rannie0705 PHE Cooler 1 1100 kg/h Alfa0706 Ice Cream freezer Hoyer0707 Centrifugal pump 1 5000 l/h APV Rosista0708 Dosing gun 4 outlets Cattabriga0711-0714 Freezing cabinet 4 200 l Brdr. Gram

3). Processed Cheese Production Machine0806 Vacuum Packer 2 25 m3/h Supervac0807 Cheese melter 1 25 l Stephan0808 Vacuum pump 1 Lohe0809 Cheese grinder 1 Kust Freres0810 Cheese crusher 1 633 kg Artofex0811 Cheese mixer 1 331 kg Artofex

Cheese cutter 1 Local made

4) Other Manufacturing EquipmentsFlow Code Machinery Name No.of items Capacity Make0607,0608 Air heaters 2 6.6 KW Novenco0901 Portable CIP unit 1 20000 l/h VM Tarm1001 Ice water plant 1 72000 Kcal/h Brdr. Gran.1002 Circulation pump 1 Grundfos1101 Steam boiler 1 800 kg/h Toma1102,1103 Boiler feed pump 2 2000 l/h Grundfos1104 Condensate tank 1 600 l Toma1105 Water softening plant 1 Silhorko1107 Oil tank 1 5000 l Roug1108 Oil pump 1 Rotan1207 Air compressor 2 32 l/min FF Luft1301 Compressor 1 19000 Kcal/h Sasbroe1302 Condenser Sdobye1302 Circulation pump 1 9m3/h Grundfos

1303 Receiver 1 20 l Sobye1304 Freyon condensing unit 1 22000 Kcal/h Sobye1305-1307 Evaporators 3 45m2 Friga Bohm1308,1310,1312 Freon condensing unit 3 7600 Kcal/h Soby1309,1311,1313 Evaporator 3 40m2 Friga Bohn1602 Diesel Generator 1 330HP Cummins

Annex 2LEGISLATIONLegal Requirements in Products: Nepal Standard

Pasteurized milk:Milk fat : min 3% (Standard milk) min 5% (whole milk)Milk SNF : min 8%Titrable acidity : max 0.2% as lactic acidTotal ash : max 0.9%TPC : max 50,000 per mlPhosphatease test : negativeColiforms : Nil

Ice Cream:

Ordinary Ice Cream Fruit/Nut/Chocolate Ice cream

Mass per liter Min. 525 kg 540 gMilk fat Min. 10% 10%Total solids Min. 36% 30%Sucrose Max. 15% 15%Titrable acidity (as per lactic acid)

Max. 0.25% -

Phosphate test Max. -Ve -Ve

Coliforms count Max. 100/g 100/gTPC Max. 2,50,000/g 2,50,000/g

Hard Cheese: Moisture : max 43.0%FDM : min 42%Edible salt : max 2.5%

Legal Requirement on Packaging MaterialAll packaging material should be of food grade.

Annex 3Specifications and Standard followedThe DDC has given following standards and recommendations in order to define good quality milk and milk products. National standards have been incorporated but in few cases the DDC standard is stricter than the national standards.

Raw Milk:Fat content: Buffalo Milk : min 5.1%

Cow Milk : min 3.1%SNF : min 8.1%Titrable acidity (as lactic acid) : less than 0.20%pH : 6.6 – 6.75Alcohol, COB Test : -veTemperature after chilling : max 5 o C recommended 3-4 o CStandard Plate Count Per ml:

Less than 200,000 : very good200,000 – 10,00,000 : good10,00,000 –50,00,000 : FairMore than 50,00,000 : Poor

MBRT Test:More than 5 hrs : very good3-4.5 hrs : good1-2.5 hrs : fair½ hr and below : poor

Yoghurt:Fat : min 3.0%SNF : min 8.0%Titrable acidity : min 0.90%pH : 3.5 – 4Phosphate test : -veColiforms count : less than 10 per mlYeast & Mold count : less than 10 per ml

Cream:Milk Fat : min 40%Titrable acidity : max 0.3%

Ice cream:Milk Fat : min 10 %SNF : min 11.5%Total milk solids : min 36%Stabilizers / Emulifiers : max 0.5%Sucrose : max 15%Titrable Acidity : max 0.25%Over run : max 90% (recommended 70-80%)Phosphatase test : -veColiforms count : less than 10 per mlTPC : less than 2,50,000 per ml

Cheese (When Sold):Yak Kanchan Buff Cheese

Moisture max 43% 43% 43%FDM min 45% 45% 45%WFFC recommended 51-52% 55-56% 55-56%Edible salt max 2.5% 2.5% 2.5%NaCl recommended 1.5-1.7% 1.5-1.7% 1.5-1.7%

All Cheese: Coliforms count : less than 10 per mlYeast & Mold count : less than 10 per ml

Water Supply:TPC at 21 o C : max 200 per ml

Recommended less than 50 per ml.TPC at 37 o C : max 20 per ml.

Recommended less than 5 per ml.Coliforms count : not detected in 1 ml

Boilers: Feed Water

Hardness : below 0.5 degree (German Degree of hardness)pH : above 9p+b value : below 1.5

Boiler WaterPhosphate : 30-60 ppmSulphite : 10-40 ppmP- value : 5-20Salt Content : below 0.5 o BeAppearance ; Clear & colorless

Annex 4

Specifications of Packaging Materials

1) Plastic Crates for Filling Milk SachetMaterial : HDPEWeight : 1.2 kg = 2% per crateCapacity : 20 Milk pouches of ½ liter capacityDimensions : Length 515 mm (inside top)

Width 200 mm (inside bottom)Height 170mm (inside Height)

Color : GreenCrates must have corporation name as Dairy Development Corporation at a place

where it can be easily seen.The Crates should be Stackable.

2) Plastic Sheets (to pack 15 kg Butter block)- Dimension:

Length 120- 125 cmWidth 90-95 cmThickness 60-70 micron

- Material: As per sample.The printing has to be in Single color as per DDC design.

3) Corrugated Fiberboard boxes:- Double wall corrugated, 5 ply- Internal diameter

For packing 15 kg of

250g Table butterfor packing 12kg of 1

kg of Ghee Containersfor packing (1/2*20kg)=

10kg ghee containersLength 37.5 cm 45cm 46.5cmWidth 31 cm 32 cm 37 cmDepth 20 cm 21 cm 13.5 cmWeight 430-450 g 530-550g 500-520g

- The box should have good resistance to water penetration and outer face should have good printability.

- Label as per design provided by DDC should be printed on two-length wise faces, single color.

- Outer and innermost layer should be made up of craft paper.- Each ply should be made up of 120-gsm papers.

4). Plastic Sachets for Paneer PackingMaterial : 3 layer co-extruded LDPE confirming to food grade.Color : TransparentPrinting : As per design and color provided by DDC.Size:

a) 205 mm * 130 mmb) 275 mm * 205 mmc) 300 mm * 245 mm

The pouches should retain vacuum for at least 7 days.

Annex 5Refrigeration cycle:The refrigeration system is vapor compression type.

Annex 6