Aavin.docx

DHARMAPURI DISTRICT CO-OPERATIVE MILK PRODUCERS' UNION LTD., KRISHNAGIRI

A REPORT ON INPLAN TRAINING TRAINING DURATION :25/02/2019 -11/03/2019

SUBMITTED BY: V.YOGESH (AC16UME200) S.SUDHARSHAN (AC16UME164) ADHIYAMAAN COLLEGE OF ENGINEERING (AUTONOMOUS), HOSUR

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AAVIN

Type

Cooperative

Genre

Milk and milk products

Predecessor

Tamil Nadu Dairy Development Corporation Limited

Founded

1958 (Tamil Nadu, India)

Headquarters

Tamil Nadu

Revenue

US$ 660 million (2012-13)

Owner

Government of Tamil Nadu

Parent

Department of Animal Husbandry, Dairying and Fisheries (Tamil Nadu)

Website

http://www.aavinmilk.com/

AAVIN is the trademark of Tamil Nadu Co-operative Milk Producers' Federation Limited, a Tamil Nadu-based milk producer's union. Aavin procures milk, processes it and sells milk and milk products to consumers.

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HISTORY The Dairy Development Department was established in Tamil Nadu in the year 1958 to oversee and regulate milk production and commercial distribution in the state. The Dairy Development Department took over control of the milk cooperatives. It was replaced by the Tamil Nadu Cooperative Milk Producers Federation Limited in the year 1981. On 1 February 1981, the commercial activities of the cooperative were handed over to Tamil Nadu Co-operative Milk Producers' Federation Limited which sold milk and milk products under the trademark "aavin". Tamil Nadu is one of the leading states in India in milk production with about 14.5 million liters per day. 'Aa' or 'ஆ' in Tamil means 'ஆஆஆ (cow)' and 'ஆஆஆஆ' means 'milk'. 'Pasuvin paal' ('ஆஆஆஆஆ ஆஆஆஆ') translates to 'cow's milk' ('ஆஆஆஆஆஆஆ ஆஆஆஆ').

ACTIVITIES The Tamil Nadu Co-operative Milk Producers' Federation Limited is an apex body of 17 District Cooperative Milk Producers' Unions. It is headquartered located at Aavin Illam, Madhavaram, Chennai and has four dairy plants at the following locations in Chennai.    

Ambattur - capacity of 4 LLPD Madhavaram - capacity of 3 LLPD Sholinganallur - capacity of 4 LLPD Ambattur - Product Dairy

These dairies collect milk from district unions, process and pack in sachets and send for sale to the consumers. The Ambattur product Dairy is engaged in the manufacture of milk products.

MILK PRODUCTS OF AAVIN Aavin produces 4 varieties of milk.    

Toned milk (3% fat) Doubled toned milk (1.5% fat) Standardized Milk (4.5% fat) Full Cream Milk (6% fat)

It is also engaged in the manufacture of milk products such milk khoa, mysorepak, gulab jamun, curd, butter milk, lassi, yoghurt and ice-creams.

as

In September 2017, Aavin announced that it would be launching seven varieties of milk-based sweets for Deepavali.

DAIRY DEVELOPMENT DEPARTMENT 4

The Dairy Development Department was established in 1958 in Tamilnadu. The administrative and statutory control over all the milk cooperatives in the State were transferred to the Dairy Development Department on 1.8.1965. The Commissioner for Milk Production and Dairy Development was made as the functional Registrar under the Tamilnadu Cooperative Societies Act. With the adoption of 'Anand pattern' in the State of Tamilnadu, Tamilnadu Co-operative Milk Producers' Federation Limited was registered in the State on 1st February 1981. The commercial activities of the Department such as Milk Procurement, Processing, Chilling, packing and sale of milk to the consumers etc., hitherto dealt with by the Tamilnadu Dairy Development Corporation Ltd., were transferred to the newly registered Tamilnadu Co-operative Milk Producers' Federation Limited,popularly known as "Aavin" As a Branding Name of the milk producers.

In the wake of liberalization policy, private dairies have also entered into the field of dairying. As per the directions of the Hon'ble Chief Minister of Tamilnadu high priority has been given for improving the performance of milk Co-operatives by adopting a systematic approach and proper strategy in Milk Co-operatives. Significant achievement has been made by Milk Producers' Cooperative Societies, Unions and Federation in the State

of

Tamilnadu.

The cattle population in India is approximately 15% of total cattle population in the world. India stood no. 1 position in milk production. Tamilnadu is one of the leading state in milk production. The milk production in Tamilnadu per day is 145.88 Lakh litres.

OBJECTIVES OF THE DAIRY DEVELOPMENT DEPARTMENT (1) To work towards bringing the un-organized dairy sector into an organized structure. (2) To supervice and regulate the activities of dairy Co-operatives. (3) To pay remunerative price to the milk producers based on the quality of milk and provide veterinary inputs and health care to increase the milk yield of milch animals. (4) To organize dairy co-operative societies in the remote villages to safeguard the milk producers from the exploitation of the private traders. (5) To ensure consistent growth of dairying on par with other enterprises. 5

(6) To ensure availability of cattle feed and green fodder to milch animals even in drought season. (7) To develop infrastructure for storage, processing and selling of milk to handle surplus milk. (8) To ensure availability of quality milk to the consumers at reasonable rates. (9) To introduce modern technology in various dairy activities. (10) To ensure availability of milk and milk products as per prescribed quality specifications.

(11) Distribution of quality milk and milk products to the consumers at reasonable price.

Keeping these objectives in mind, a number of activities are undertaken by the Dairy Development Department, viz., Provision of free veterinary health cover to all animals owned by the members of milk cooperatives, implementation of Artificial Insemination Programme, supply of balanced cattle feed and inculcation of farmers with the

modern

animal

husbandry

methods

and

practices.

All activities, which are essential for the up gradation of the milch animals and improving

their

productivity

in

the

long

run,

have

been

undertaken.

Provision of necessary infrastructure facilities for marketing milk and milk products and supply of quality milk to the consumer has been made by way of establishing new chilling centres, pasteurization plants and adoption of modern processing system.

STRATEGIES

ADOPTED

TO

ACHIEVE

THE

OBJECTIVES

To achieve the objectives of the Dairy Development Department the following activities are being undertaken: (1) Hygienic and pure milk and milk products are made available to the consumers. (2) Computerization of dairy activities to ensure transparency in administration.

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(3) Providing free veterinary health cover, Artificial Insemination service to cattle, insurance of cattle, supply of balanced cattle feed, inputs like fodder seeds and cuttings for fodder cultivation to milk producers in co-operative sector. (4) Strengthening of clean milk production at village level through necessary education and milk testing. (5) Implementation of various State and Central Government Schemes. (6) Strengthening and increasing the handling capacity of Dairies functioning in Dairy Co-operative sector. (7) Opening of new parlours, sales points, new milk routes, consumer societies and sale of milk cards.

THE DEPARTMENTAL SET UP OF THE CO OPERATIVE SOCITIES The Commissioner for Milk Production and Dairy Development is the Head of the Dairy Development Department. He is the functional registrar in respect of Dairy Cooperatives in the State. He is also the Ex-officio Managing Director of the Tamilnadu Cooperative Milk Producers' Federation Limited. i.e. Aavin.

The Commissioner for Milk Production and Dairy Development exercises all the statutory powers with regard to the registration of societies, supervision, inspection, inquiry, disputes, liquidation of milk cooperatives including the District Cooperative Milk Producers' Unions and Federation under the relevant provisions of the Tamilnadu Cooperative Societies Act, 1983 and Tamilnadu Cooperative Societies Rules, 1988. While discharging the statutory functions, the Commissioner for Milk Production and Dairy Development is assisted by the Deputy Milk Commissioner (Co-operation) and a Deputy Registrar at the Headquarters besides 29 Deputy Registrars (Dairying) at the District level by way of conferring the powers of the functional Registrar.

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FUNCTIONS OF THE DAIRY DEVELOPMENT DEPARTMENT The main functions of the Dairy Development Department include Organisation of societies, registration of societies, supervision and control of primary milk cooperatives, District Cooperative Milk Producers Unions and Tamilnadu Cooperative Milk Producers Federation.

The Dairy Development Department exercises statutory function - like Inquiry, Inspection, Surcharge and Super session, appointment of special officers, liquidation and winding up of dormant Societies etc. The Commissioner for Milk Production and Dairy Development, Deputy Milk Commissioner (Co-operation), and Circle Deputy Registrars (Dairying) are vested with quasi-Judicial powers in respect of settlement of disputes, appeal, revision and review under various provisions of Tamilnadu Cooperative Societies Act, 1983 & the Tamilnadu Cooperative societies Rules, 1988 made there under.

PRIMARY DAIRY COOPERATIVES MILK SOCIETIES A minimum of 25 or more individuals competent to contract under section 11 of the Indian Contract Act of 1872, owning milch animals, can form a Primary Dairy Cooperative Society, with one or more villages as its area of operation. Such persons have to approach the Circle Deputy Registrar's (Dairying) office functioning at the District for further guidance. The members of Primary Cooperative milk society have to supply milk to the Society which will procure milk on quality basis and they will receive milk cost once in 10 days / 15 days from the Society. Milch animals are provided with free veterinary health cover, artificial insemination and the supply of balanced cattle feed. Inductions of farmers on modern animal husbandry practices are aimed at by upgrading the milch animals and thereby improving their productivity in the long run for the benefit of the members.

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WOMEN MILK PRODUCERS’ COOPERATIVE SOCIETIES In order to encourage the women members to contribute more to the dairy sector, they are being called upon to organise women milk producers' cooperative societies in their respective areas. There are 1793 women milk Producers’ cooperative societies functioning in Tamilnadu.

ELECTIONS TO DAIRY CO-OPERATIVES Primary Milk Cooperative Societies and District cooperative Milk Producers Unions and Federation were administered by elected Boards. The CMPDD is functioning as District Election Officers for the dairy co-operatives. Under the supervision of the State Cooperative Election Commission elections were conducted for the Board of Directors of dairy cooperatives at all the three levels in 2013 and elected boards assumed charge on 09.05.2013 at primary levels, on 11.06.2013 at district level and on 17.07.2013 in the State Federation. On formation of new societies, elections are conducted within a period of six months. Democratic spirit of cooperative movement can be seen from the fact that 1,09,891 board of directors, of which 35,592 are women, are involved in the administration of dairy cooperatives across the state.

FUNCTIONS OF DISTRICT COOPERATIVE MILK PRODUCERS UNIONS There are 17 District Cooperative Milk Producers' Unions functioning in the State of Tamilnadu covering 30 Districts. There are 18 Dairies in District Co-operative Milk Producers' Unions with an installed processing capacity of 27.07 llpd. There are 35 Chilling Centres (Functional) in District Co-operative Milk Producers' Unions with installed chilling capacities of 14.75 LLPD.

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THE FUNCTIONS ARE :

(1) Establishment of chilling centres

(2) Formation of new milk routes to collect milk produced by the members of the societies.

(3) Collection of milk from societies, process and pack in modern dairy plants by maintaining quality standards.

(4) Supply of quality milk to Chennai Metro under hygienic conditions.

(5) Fixation of procurement and selling price of Milk

(6) Increase of liquid milk sales by introducing innovative sales promotional activities.

(7) Supply of inputs to the members of the societies.

(8) Render Veterinary Health Service and emergency service to the cattle of members of primaries, to impart training on First aid and on Artificial insemination to the staff of member societies.

(9) Extending Artificial insemination services to the cattle owned by the members of Milk Cooperative Societies.

(10) Providing milk cans, Milk Analyser and LN2 containers.

(11) Salem, Erode, Madurai and Dharmapuri Unions are the Feeder Balancing Dairies. Surplus milk in the District Unions, after meeting their local sales is diverted to the nearest Feeder Balancing Dairies for conversion into milk products, such as Skim Milk Powder, Butter and Ghee.

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(12) The three Cattle Feed Plants at Madhavaram, Erode and Kappalur are run by the Kancheepuram - Tiruvallur Union, Erode Union, Madurai Union respectively. The production capacity of these cattle feed plants is 100 MT per day each. The balanced cattle feed produced in the form of pellets and mash are supplied to the members of the Milk Co-operatives, livestock farms manned by the Animal Husbandry Department and to various local bodies including the Corporation of Chennai.

FUNCTIONS OF FEDERATION (TCMPF)

The Tamilnadu Co-operative Milk Producers' Federation Limited is an apex body of 17 District Cooperative Milk Producers' Unions. The Federation has four dairy plants in Chennai, one at Ambattur with a capacity of 4.00 lakh litres per day, another at Madhavaram with a capacity of 3.50 lakh litres per day and the third dairy at Sholinganallur with a capacity of 4.00 lakh litres per day. These dairies collect milk from District Unions process and pack in sachets and send for sale to the consumers in and around Chennai City. The fourth product dairy at Ambattur with a capacity of 65,000 LPD is engaged in the manufacture of milk products such as Yogurt, ice cream, Khova, Kulab jamoon, Buttermilk, Curd and Mysore pa. Apart from the above, a fifty DCPP has been established at Tiruvannamalai with a capacity of 2 LLPD and 20 MT since 2015.

MILK PROCUREMENT BY DCMPUs: PRICE REVISION

Most of the rural people especially women make their livelihood by rearing milch animals and by supplying milk to the Co-operatives. Keeping this in view and to improve the rural economy and to enhance the personal income of the stake holders in rural area, Government of Tamilnadu directed the Tamilnadu Co-operative Milk Producers’ Federation and District Co-operative Milk Producers’ Union to raise the procurement price of the cow's milk from Rs.23.00 to Rs.28.00 per litre and that of the buffalo’s milk from Rs.31.00 to Rs.35.00 with effect from 01.11.2014 and the milk cost as per the revised procurement price is being disbursed to the Milk producers.

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Average milk procurement in DCMPUs in lakh litres per day. Year 2005-2006

21.59

Year 2006-2007

22.10

Year 2007-2008

21.64

Year 2008-2009

22.00

Year 2009-2010

22.30

Year 2010-2011

20.66

Year 2011-2012

21.40

Year 2012-2013

24.36

Year 2013-2014

23.22

Year 2014-2015

23.68

Year 2015-2016

28.97

Year 2016-2017

28.50

MARKETING: The three wings are carrying out the marketing of milk and milk products of the Federation namely: 1. Metro Liquid milk marketing. 2. Metro Milk Product marketing. 3. Up country marketing.

The product wing of the Federation located at Nandanam directly carries of marketing of the products in Chennai Metro and suburbs. The products are stored at the Godown at Ambattur and distributed to the outlets. The sale of milk in sachets is being carried out through 16 zones, 292 Federation Depots, 184 Fedn. Distribution Points, 38 Whole Sale Milk Distributors, 89 Milk Retailers and 49 Milk Consumers’ Co-operative Societies and their depots numbering 221 and 142 distribution points. The sale of milk product is being carried out through 25 parlours, 145 Franchise Retail Outlets (FROs), 11 Wholesale dealers, and 2824 Retailers. The Federation also caters to the needs for functions like marriages by booking Special Orders. 12

CENTRALLY SPONSORED SCHEMES Presently Strengthening Infrastructure for Quality and Clean Milk Production (SIQ&CMP) in Erode, IDDP in Thanjavur,and ACS in Thanjavur and Kancheepuram – Tiruvallur which were sanctioned prior to 2014 -15 are being continued under NPDD. 1. Strengthening

Infrastructure for Quality and

Clean Milk Production

(SIQ&CMP) This scheme is being implemented in Erode. Out of Rs.499.94 Lakh, so far Rs.327.91 Lakh has been released. The balance amount of Rs.172.03 Lakh is awaited. All major components like BMC installation, supply of chemicals, utensils, milking machines and strengthening of laboratories, etc.have been completed. 2. Assistance to Cooperatives (ACS) It is being implemented in Kancheepuram – Tiruvallur Union and Thanjavur Unions. The scheme supports the payment of dues to milk producers, settlement of gratuity dues to employees and payment due to other Unions. The entire fund for Kancheepuram – Tiruvallur Union has been received while the final fund of Rs.62.07 Lakhfor Thanjavur Union is awaited from Govt. of India.The state share of Rs.98.86 Lakh forKancheepuram – Tiruvallur Union and Rs.62.07 Lakh for Thanjavur Union is also awaited. 3. IDDP Scheme

Thanjavur, Pudukottai and Virudhunagar Unions have received their total final installment of Rs 262.08 Lakh towards improving milk procurement, infrastructure for milk processing & marketing and development of human resources. SIGNIFICANT INFORMATION

Sno Items

Achievement as on 31/03/2017

1.

Total number of functional Milk Producers’ Co-operative 12232 Societies

2.

New MPCS organized

137

3.

Total number of Members in Milk Co-operative Societies.

20.04 Lakh

4.

Total No. of pouring members

4.60 lakh

5.

Milk Production by societies

31.36 LLPD

6.

No. of District Unions

17 13

7.

State Level Federation

1

8.

Milk Procurement by Unions

26-31 LLPD

9.

Milk Marketing in Chennai City

11.22 LLPD

10.

Milk Marketing in District Unions.

9.29 LLPD

11.

Number of Union Dairies

18

12.

No. of Federation dairies

5

13.

Handling Capacity Union Dairies

27.07 LLPD

14.

Handling Capacity Federation Dairies

14.15 LLPD

15.

Number of Chilling Centres (Functional)

35

16.

Handling Capacity of Chilling Centres

14.75 LLPD

17.

No. of BMC units functioning

326

18.

Handling capacity of BMC

14.39 LLPD

19.

No. of rural milk collection routes

530

20.

No. of milk distribution routes at District level

266

21.

No. of milk distribution routes at Chennai Metro (Sachet, 132 Bulk Vending and By products)

22.

No. of Powder Plants

5

23.

Capacity for drying milk

90 MTs

Products available Pasteurized

Toned

Standardized

Full

Double

Ghee varieties

Milk FAT

milk

cream

toned

FAT

milk FAT 6

3.0%

4.5%

%

SNF

8.5%

SNF

8.5%

SNF

9.0%

Milk FAT 1.5 % SNF 9.0 %

GHEE (TIN)

15KG

GHEE (JAR)

5LTR

GHEE (TIN)

1LTR 14

GHEE (JAR)

1LTR

GHEE (CARTON)

1LTR

GHEE (TIN)

500ML

GHEE (JAR)

500ML

GHEE (CARTON)

500ML

GHEE (JAR)

200ML

GHEE (SACHET)

25ML

GHEE (JAR)

5KG

GHEE (JAR)

1KG

GHEE (JAR)

500GM

GHEE (JAR)

200GM



Carton - 500gms



Poly Bag - 1 kg



Bulk Bag - 25 kg

Cheese



200gms/400gms

Flavoured Milk



Tetra Pak & bottles 200ml



-strawberry

Skimmed Milk Powder

-cardamom -chocolate -Pineapple -Pista 

UHT Milk

1000 ml (Tetra Brik Aseptic Package)



500 ml (Tetra Fino Aseptic Package)



Ice-creams Vanilla,

Strawberry,

Chocolate,

Cups 50gms/100gms/500gms / 1lit / 1 gallon 15

Pista,



Sticks

Badam, Chaco Risin, Mango, Butter



Cones



Cartons

Pineapple,

Scotch,

Blackcurrant,

Tutti

Frutti,

Sugar Free Ice creams Milk

Sweets

Gulab Jamun, Mysurpa, Dates Khoa

250

gms/

500gms/1kg



Butter

-

Salted - 200gms / 500gms / 20kg



Plain - 200gms / 500gms / 20kg

Masala

Butter

Milk &

Sachet

Lussi

-

200ml

100 ml

Yoghurt 

Mango Drink - Maavin

200 ml (Tetra Brik Aseptic Package)

Milk

Khoa



Packets

-

gms/50gms/100gms

25 -

/250gms/500gms 

Panneer CURD

Bulk

-

Un

sugared

200gms 200 ml sachet & 200 GMS CUP(Probiotic)

BRIEF NOTE AS OF 01.06.2017 JMD’S UNIT

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The Tamilnadu Co-operative Milk Producers ’ Federation Limited (TCMPF Ltd.) is a co-operative institution registered under the Tamilnadu Co-operative Act and functioning similar to Anand pattern i.e. three tier system. The objective of the Federation is to promote the economic development of the farming community by procurement of milk from villages, processing of milk and manufacturing of milk products. The major activities of the Joint Managing Director ’s Unit are transporting, receiving, processing, packing and marketing of milk from Dairies situated at Madhavaram, Ambatur and Sholinganallur and milk products from Product Dairy, Ambattur. In TCMPF Ltd. JMD ’s Unit is functioning under the following units headed by Joint Managing Director. Joint Managing Director’s Office (JMD’s Office). Ambattur/Madhavaram/Sholinganallur Metro Milk Dairies. Product Dairy, Ambattur. Milk Marketing & Product Marketing Division, Nandanam Transport Unit Quality wing General Stores Dairy cum powder plant at TV Malai 1. JMD’s Office:

The above mentioned units (Sl.No.2 to 8) are functioning under the control of Joint Managing Director ’s Office.

The activities of milk and milk products, processing, production, marketing, quality and transport are controlled by the Joint Managing Director. All the materials for milk packing and by product packing and machines are purchased in the JMD ’s office by the order of the Joint Managing Director.

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Further, the action for filling up of Technician posts required for the Metro Dairies is done at JMD ’s Office as per the orders of Head Office.

2. Ambattur / Madhavaram / Sholinganallur MetroMilk Dairies:

From the above said three Milk Metro Dairies, 11,50,000 Lakhs Litres of milk average per day is processed, packed and supplied to metro marketing for sales around the Chennai and Chennai City.

The following four types of milk procured and supplied. Full Cream Milk(FCM – 6% Fat, 9%SNF) Standardized Milk (SM – 4.5% Fat, 8.5% SNF) Toned Milk (TM – 3% Fat, 8.5% SNF) Double Toned Milk(DTM – 1.5% Fat, 9%SNF) and From Ambattur Dairy – Flavoured Milk is manufactured and supplied to the market for sales. 3) Product Dairy, Ambattur: In the Product Dairy, the following products are manufactured and supplied to the market for sales. Ice Cream (13 Varieties) Yoghurt Khoa Curd (3 Varieties) Butter Milk Gulab Jamun Mysorepa Dates Khoa Panner Lassi (2 Varieties) Milk Peta Chocolate 18

4. Milk Marketing & Product Marketing Division:

The following three marketing divisions are functioning under the corporate office, marketing unit headed by the General Manager (Mkg.). Madhavaram Marketing Division (North Division) Ambattur Marketing Division (Central Division) and Sholinganallur Marketing Division (South Division)

11,50,000 Lakh Litres average per day, milk has been procured and supplied to the Chennai City and around the Chennai City in the form of Sachet Milk through 119 milk route vehicle from Ambattur, Madhavaram and Sholinganallur Metro Dairies.

Milk has been sold through Federation Depots, Co-operative Society Depots, AVM Unit and Whole Sale Dealers.

Milk products are sent to the market through 17 product route vehicles for sales and 3 ice cream freezer vehicles.

The Butter, Ghee, Skimmed Milk Powder, Tetra Milk, Flavoured Milk received from the various Dist. Co-op. Milk Proucers ’ Unions are also sent to market for sales through the above said product route vehicles.

The milk and milk products sales are controlled by the various Zonal Offices in Chennai City.

5.Transport Unit: In TCMPF, the activities of purchase and maintenance of milk tankers, Light Vehicles and Heavy Vehicles are dealt by the Transport Unit. Milk received from the various Dist. Unions to Metro Dairies and supplied to the market for sales through milk tankers are controlled by this unit.

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6.Quality Wing: One Quality Control Lab is functioning in each Dairy under the direct control of the Joint Managing Director. Checking the quality of milk and milk products right from its production till it reaches to the consumers. Checking the quality of milk received from the Dist. Unions. Checking of quality of milk products dispatched from Products Dairy and District Unions.

7. Dairy Cum Powder Plant at Ammapalayam The Dairy Cum Powder Plant, Thiruvannamalai is formed under a total source of funds 7048 Lakhs Handling Capacity: Liquid Milk handling : 2.2. Lakhs / Day ( Type of Milk : whole Milk + Skimmed Milk) Butter Production : 9.0 MT/Day Skimmed Milk Powder(Agglomerated): 19 MT/Day MANPOWER DETAILS (as on 01.06.2017)

Sl. No.

Name of Unit

No. of employees working

1.

JMD’s Office

2.

Ambattur Dairy

161

Central Dairy

187

4.

Sholinganallur Dairy

117

5.

Product Dairy

94

6.

Marketing Unit

340

7.

QC Wing

8.

Transport Unit

9

DCPP T.V.Malai

3.

Total

72

69 207 59 1306

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DHARMAPURI DISTRICT CO-OPERATIVE MILK PRODUCERS' UNION LTD., KRISHNAGIRI

The Products Produced in This Branch are: •

Pasteurized toned Milk (or) Standardized Milk

•

Full Cream Milk or Double Toned Milk

•

Ghee

•

Skimmed Milk Powder

•

Ice –Cream (Kulfi)

•

Butter

•

Curd

•

Butter Milk

Each of the above products has its own manufacturing methodology

Before the Products have been Manufactured in its specific methodologies the pre processing of the Raw milk has been carried out in the Production Department. PRODUCTION DEPARTMENT: Production is an important function in every organization. In aavin the production can be maintained by process and maintenance department. Milk is the main product for Aavin and other milk products also produced by Avian. It helps to reduce the spoilage of milk and help to increase the profit for the trade union. There are four managers in production department. They are manager (process and maintain), manager (dairying), manager (pre-packing), manager (packing). In a process & maintain section and pre-packing section, they have operator for supervising the machineries operation. The production processes functions as three shifts for a day. The shift timing as follows, 1st shift – From 6am to 2pm 2nd shift – from 2pm to 10pm 3rd shift – from 10pm to 6pm

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PRODUCTION PROCESS: Raw milk

Plenture

Sample for lab test

Weighing

Chilling (40˚C)

Stored in silo

Standardisation

Pasteurisation

Homogenize

Regeneration 1 (10˚- 80˚)

Holding

Regeneration 2 (80˚- 10˚)

Store in 4˚C

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1) Milk reception: The manufacturing process starts from milk reception. The procurement section duty ends with this reception after it is carried out by process and maintain department. The milk reception has sufficient facilities for parking the vans and tracks for collection ˚of milk carried in to the factory. In the reception the milk received by the canisters from village societies and tankers from BMC’s or other unions. 2) Plenture: In this process the equipment used for finding curdling of milk is called as plenture. It helps to detecting the curdling and reduces the spoilage of milk. It is the preliminary test done by the experienced staffs only. 3) Sample for lab test: After plenturing, sample can be taken for testing the fat percentage and other testing. The test is done by quality control department. 4) Weighing: The milk weight calculated in the modern weighing machine. The weight is calculated in kilo grams and it is converted to liters. 5) Chilling: The first step in processing of milk is chilling. Chilling of raw milk is to increase life to the milk and to check the growth of micro organism present in the milk and arrest further determination in quality to raw milk. The freshly downed raw milk has been chilled to 4˚C and temperature until the milk processed. 6) Stored in silo: After finishing of chilling process the milk is stored in large size silo which has a capacity of 66,000 liters. This function helps to balance the fat contents. The temperature is maintained as 5˚C and below. 7) Standardization: The next important step in processing is standardization of milk refuse to the quality adjustment that is raising or decreasing of fats or solid non-fat percentage of milk to desired level. The societies have to confirm to the legal and other requirement prescribed in this regard. This standardization makes aavin milk as high quality milk and creates demand among the people. 8) Pasteurization:

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Demonstrates that healing wine to kill the micro organisms and helps in preservation. The application of this process gives rise to the term pasteurization. 9) Homogenization: It means fat globules in the milk are subdivided into small particles of uniform size after which the supply is done. The fat cannot be separated from the homogenized milk. 10) Regeneration – 1: It is the main function in every milk processing unit. It just process of milk protecting from spoilage and increasing its expiry time as more than one day. It usually followed in every home. In this process the milk’s temperature increased from 10˚C to 80˚C. The regeneration machine has four stages. The stage wise temperature given as below, 1st stage - 10˚C 2nd stage - 50˚C 3rd stage – 60˚C 4th stage - 80˚C 11) Holding: After finishing the regeneration 1st process the milk hold in holding tubes. These are steel tubes designed as zing-sang method for milk getting same heat. After the holding is end the milk sent to next level. 12) Regeneration – 2: This is the process just opposite to regeneration -1. In the second regeneration process milk’s temperature can decrease from 80˚C to 10˚C. It is the last stage in the processing.

13) Final storage: Madurai aavin’s main dairy have 6 storage silos. After finishing of all the above processes, the milk is stored in the silos for pre-packing. At the time of storage the milk’s temperature maintained as 4˚C. The silo has the capacity of 6000liters.

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14) Pre-packing section: It is the final stage in the production of milk. Pre-packing section has one manager and assistant staff for operating the function. The pre-packing section depends on both manual and machinery works. In this section milk and curd are packed. The milk is taken from storage silos through pipes and it is sent to the pre-packing machine and the milk is packed in poly ethylene packets. There are 13 milk packing machines and 1 curd packing machine in the pre-packing section. This machine prints the date of manufacturing and it has the UV light on the top of its head. This light helps to kill the bacteria in the packing cover. The pre-packing function starts from rinsing of grade (tray). The rinsing function is done by automatic machine with water and sodium hydracids powder. After rinsing the grade moved from the rinsing machine to packing machine. The women workers arrange the milk packets in the trays. Each grade has 12 liters capacity. At last the grades will be sent to the cooling chambers for storing with minimum ˚C

The packed milk has been sent for the commercial purposes for selling etc,. the milk has to be maintained at the 5˚C throught the processing , packaging, storing, transporting and finally to the hands of the customers. In the Krishnagiri Aavin the Daily milk input is over 2.5 Lakh liter s of Milk in which only 30,000 Liters of milk is sent for commercial usage The rest of milk were sent for head offices according to the requirement before that they were pre processed. The pre processed milks were sent via tankers with proper insulation and cooling fascilities. 25

THE IMPORTANT MACHINERIES USED ARE: •

SYLO: Milk storing Device

•

CREAM SEPERATOR: Separates cream from milk.

•

PASTEURIZER : in which pasteurization process is carried out.

•

HOMOGENIZER: In which fat particles are broke down to fine particles.

•

CONVEYOR BELTS: to transmit the products

•

VESSEL CLEANERS: to clean the vessles

•

PRE PACKING MACHINE : To pack the milk

•

SEALING MACHINE

•

MILK POWDER MANUFACTURING MACHINES etc

THE VERY IMPORTANT SECTIONS IN A DIARY ARE:  BOILER SECTION  REFRIGERATION SECTION

BOILER: A boiler is a closed vessel in which fluid (generally water) is heated. The fluid does not necessarily boil. The heated or vaporized fluid exits the boiler for use in various processes or heating applications including water heating, central heating, boiler-based power generation, cooking, and sanitation.

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There are three number of boilers in this Firm : They are 1. Shellmax Thermax Boiler 2Ton

CAPACITY

2000Kg/Hr

HEATING SURFACE

44m2

WORK PRESSURE

9Kg/Cm2

HYDRAULLIC PRESSURE

10 Kg/Cm2

TUBES

88

FUEL

Furnace Oil

2.Shellmax Thermax Boiler 2Ton

CAPACITY

2000Kg/Hr

HEATING SURFACE

44m2

WORK PRESSURE

9Kg/Cm2

HYDRAULLIC PRESSURE

10 Kg/Cm2

TUBES

88

FUEL

Furnace Oil

2. Premier Boiler

CAPACITY

4000Kg/Hr

HEATING SURFACE

136m2

WORK PRESSURE

17.58Kg/Cm2

TUBES

168

FUEL

Furnace Oil

This is the most advanced and automated Boiler system

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REFRIGERATION: Refrigeration is a process of removing heat from a low-temperature reservoir and transferring it to a high-temperature reservoir. The work of heat transfer is traditionally driven by mechanical means, but can also be driven by heat, magnetism, electricity, laser, or other means. Refrigeration has many applications, including, but not limited to: household refrigerators, industrial freezers, cryogenics, and air conditioning. Heat pumps may use the heat output of the refrigeration process, and also may be designed to be reversible, but are otherwise similar to air conditioning units.

Gas cycle When the working fluid is a gas that is compressed and expanded but doesn't change phase, the refrigeration cycle is called a gas cycle. Air is most often this working fluid. As 28

there is no condensation and evaporation intended in a gas cycle, components corresponding to the condenser and evaporator in a vapor compression cycle are the hot and cold gas-to-gas heat exchangers in gas cycles. The gas cycle is less efficient than the vapor compression cycle because the gas cycle works on the reverse Brayton cycle instead of the reverse Rankine cycle. As such the working fluid does not receive and reject heat at constant temperature. In the gas cycle, the refrigeration effect is equal to the product of the specific heat of the gas and the rise in temperature of the gas in the low temperature side. Therefore, for the same cooling load, a gas refrigeration cycle needs a large mass flow rate and is bulky. Because of their lower efficiency and larger bulk, air cycle coolers are not often used nowadays in terrestrial cooling devices. However, the air cycle machine is very common on gas turbine-powered jet aircraft as cooling and ventilation units, because compressed air is readily available from the engines' compressor sections. Such units also serve the purpose of pressurizing the aircraft. In this firm the refriferation has been used for the two purposes they are 1.Processing 2.Storing The various compressor specification are: For Butter Storing: 6X6 compressor 4X4 Booster compressor 456Xl Compressor Components of the Refrigeration System are: 1. Water Storage Tanks X 4 of each 50000 liters of capacity 2. Reciver 3. Filter 4. Accumulator 5. Aggitator 6. Compressors 7. Oil seperators 8. Taps etc,. Out of all above components Compressor plays a Vital role in cooling:

6X6 Ammonia compressor Motor

35 Hp

Capacity

30 Tr 29

4X4 Booster compressor for6X6 Capacity

20 Tr

6X6 Ammonia compressor Motor

35 Hp

Capacity

30 Tr

9X9Ammonia compressor Motor

135 Hp

Capacity

70 Tr

The gases used for the cooling operation are: 1. Ammonia (Nh3) 2. R22 3. R32 4. R134 5. R410

REFRIGERATION SYSTEMS FOR MILK COOLING Milk must be cooled from 98 degrees F. (37 degrees C.) to storage temperature, typically about 38 degrees F., to preserve its quality. The cooling process involves removing 56 BTUs of energy from each pound of milk (27 kilojoule per kg). Typically, a refrigeration system does this by using a special refrigerant fluid to remove heat from the milk and “reject” the heat (usually) into the outside air. The basic refrigeration system is made up of a refrigerated bulk tank, a refrigeration compressor unit and an air-cooled condenser unit. There are several technologies that can be added to the milk cooling systems on dairy farms to reduce the refrigeration requirements or to capture waste heat for pre-heating water: 

Refrigeration heat recovery (RHR) units will make a refrigeration system more efficient by collecting heat that would normally be wasted to the air and using it for water heating. An RHR unit captures heat from the system refrigerant and transfers it to water, preheating it before it enters a water heater.

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

Scroll compressors are 15 to 20% more efficient than traditional reciprocation compressors yet have fewer moving parts and are only slightly more expensive than reciprocating compressors. Scroll compressors have been used in the dairy industry with good results for over 15 years. If you are purchasing a new bulk tank or replacing a failed reciprocating compressor, you should specify that the compressors be a scroll type. The additional investment is a modest cost for the improvement in efficiency.



Well Water Precoolers are heat exchangers that use well water to cool the milk before it reaches the bulk tank. Properly sized, they can reduce milk cooling costs by up to 60%, assuming 55°F well water. Undersized water lines and water system capacity are the two largest reasons that precoolers do not perform up to their potential. Caution: If an RHR unit is being used on the dairy, an energy audit should be done, as precoolers and RHR units are competing technologies. It is usually more cost effective to maximize water heating with an RHR than precooler.

It is also important to keep a farm’s refrigeration system clean and well maintained. Dirty coils or low refrigerant pressures will reduce efficiency and increase operating costs. Many systems have a “watch glass” that can be used to determine if the refrigerant needs to be recharged – if the fluid in the watch glass is bubbly instead of clear, it is time to call your refrigeration technician and schedule a service.

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MILK PRODUCTS MANUFACTURING SYSTEM:

1.GHEE Ghee is typically prepared by simmering butter, which is churned from cream (traditionally made by churning dahi), skimming any impurities from the surface, then pouring and retaining the clear liquid fat while discarding the solid residue that has settled to the bottom. Spices can be added for flavor. The texture, color and taste of ghee depends on the quality of the butter, the milk source used in the process and the duration of time spent boiling

2.BUTTER Butter is a dairy product with high butterfat content which is solid when chilled and at room temperature in some regions, and liquid when warmed. It is made by churning fresh or fermented cream or milk to separate the butterfat from the buttermilk. It is generally used as a spread on plain or toasted bread products and a condiment on cooked vegetables, as well as in cooking, such as baking, sauce making, and pan frying. Butter consists of butterfat, milk proteins and water, and often added salt.

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Most frequently made from cow's milk, butter can also be manufactured from the milk of other mammals, including sheep, goats, buffalo, and yaks. Salt (such as dairy salt), flavorings (such as garlic) and preservatives are sometimes added to butter. Rendering butter, removing the water and milk solids, produces clarified butter or ghee, which is almost entirely butterfat. Butter is a water-in-oil emulsion resulting from an inversion of the cream, where the milk proteins are the emulsifiers. Butter remains a firm solid when refrigerated, but softens to a spreadable consistency at room temperature, and melts to a thin liquid consistency at 32 to 35 °C (90 to 95 °F). The density of butter is 911 grams per Litre (0.950 lb per US pint).[1] It generally has a pale yellow color, but varies from deep yellow to nearly white. Its natural, unmodified color is dependent on the source animal's feed and genetics, but the commercial manufacturing process commonly manipulates the color with food colorings like annatto or carotene. 3.CURD: Curds are a dairy product obtained by coagulating milk in a process called curdling. The coagulation can be caused by adding rennet or any edible acidic substance such as lemon juice or vinegar, and then allowing it to coagulate. The increased acidity causes the milk proteins (casein) to tangle into solid masses, or curds. Milk that has been left to sour (raw milk alone or pasteurized milk with added lactic acid bacteria) will also naturally produce curds, and sour milk cheeses are produced this way. Producing cheese curds is one of the first steps in cheesemaking; the curds are pressed and drained to varying amounts for different styles of cheese and different secondary agents (molds for blue cheeses, etc.) are introduced before the desired aging finishes the cheese. The remaining liquid, which contains only whey proteins, is the whey. In cow's milk, 90 percent of the proteins are caseins. There are two methods to make curd, with rennet and with acid. Using acid, like lemon juice, to make curd releases the lactose into the water. Thus the solid curd formed from this method is good for people with lactose intolerance. This type of curd is known as Chhena in India. Using rennet to make curd, attaches the lactose to the solid coagulated proteins. Thus it is not recommended for people with lactose intolerance. This type of curd is the commercial cheese available in supermarkets, such as Cheddar, Mozzarella, Swiz, Parmesan. Vegetarian rennet, usually from Withania coagulans, is used to make paneer in India. 4.MILK POWDER Powdered milk or dried milk is a manufactured dairy product made by evaporating milk to dryness. One purpose of drying milk is to preserve it; milk powder has a far longer shelf life than liquid milk and does not need to be refrigerated, due to its low moisture content. Another purpose is to reduce its bulk for economy of transportation. Powdered milk and dairy products include such items as dry whole milk, nonfat (skimmed) dry milk, dry buttermilk, dry whey products and dry dairy blends. Many dairy products exported conform to standards laid out in Codex Alimentarius. Many forms of milk powder are traded on exchanges. 33

Powdered milk is used for food and health (nutrition), and also in biotechnology (saturating agent) In modern times, powdered milk is usually made by spray drying[6] nonfat skimmed milk, whole milk, buttermilk or whey. Pasteurized milk is first concentrated in an evaporator to approximately 50 percent milk solids. The resulting concentrated milk is then sprayed into a heated chamber where the water almost instantly evaporates, leaving fine particles of powdered milk solids. Alternatively, the milk can be dried by drum drying. Milk is applied as a thin film to the surface of a heated drum, and the dried milk solids are then scraped off. However, powdered milk made this way tends to have a cooked flavour, due to caramelization caused by greater heat exposure 5.ICE CREAM Ice cream is made from a blend of dairy products (cream, condensed milk, butterfat), sugar, flavorings, and federally approved additives. ... The additives, which act as emulsifiers and stabilizers, are used to prevent heat shock and the formation of icecrystals during the production process. 6.BUTTER MILK

Traditional buttermilk is what is left over after butter is made from sour cream. During the churning of the milk, the milk fat globule membranes break, making the milkfat curdle together. ... Nowadays, for this reason, almost all buttermilk is produced by adding lactic acid bacteria to pasteurized skimmed milk

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