AN IN PLANT TRAINING REPORT ON:

NMC DAIRY INDUSTRY

Shrawan - Bhadra 2074

By

Ruja Subedi

B.tech 8th semester

College of Applied Food and Dairy Technology (CAFODAT),

Purbanchal University
Minbhawan, Kathmandu, Nepal

Submitted to:

NMC Dairy Industry

Mechinagar- 08, Itavatta, Jhapa

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 ACKNOWLEDGEMENT

I would like to express my deepest appreciation to all those who provided me the possibility
to complete this report. A special gratitude I would like to give to the Managing Director
Professor Shyam Kumar Mishra for providing an opportunity to carry out my In plant
Training in NEPAL MULTI PURPOSE COOPERATIVE DAIRY (NMC) Dairy Industry.

Also I would like to mention Production Officer Mr Bharat Mani Poudel along with all
Production staffs, Chief administrative officer, Chief marketing officer, Extension officer,
production staffs and administrative staffs for their constant support and guidance during my
training period.

Furthermore I would like to acknowledge with much appreciation to Quality Control Officer
MS Karishma Pradhan for her direction, guidance, encouragement and her support in
different ways throughout my working period, And also for her stimulating suggestions that
helped me especially in writing this report.
I am thankful to all the crucial role of the staff of NMC Dairy, who gave the permission to
use all required equipment and for providing the data and information along with all
necessary material to complete the task.
More words of appreciation goes to my teachers from CAFODAT College who guided me to
complete the training successfully.

Last but not least, many thanks goes to all technical and non technical staffs of NMC Dairy
Industry as well as to those who directly and indirectly supported me during my internship
days.

MS.RUJA SUBEDI

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1. Introduction:

NMC Dairy Industry is the leading dairy industry of eastern Nepal. NMC dairy is financed by
Nepal Multipurpose Cooperative Society itself on the investment of 12 crores, located at
Mechinagar-8, Itavatta, Jhapa. Dairy plant acquires 4/5 of total area, which is 5 kathaha. NMC
Dairy supplies quality products of varieties with name of product: Kanchan. Since its
inception, it has been growing steadily and broadening the customer base. Today, NMC Dairy
is growing faster than ever anticipated because of its keen interest in consumers’ satisfaction.
NMC Dairy today has been making the finest quality Dairy Products. What appreciates it
most is its skill in diversification to various dairy based products according to the consumers'
taste like sweets and fast foods. It has dedicated its business to the rural milk producers and
urban milk consumers of Jhapa. It safeguards the interest of the rural milk producers by
providing highly competitive price and is committed to providing the highest quality product
to consumers’ at the most reasonable cost.
It is a company with the total no. of workers of about 65.It provides lots of facilities to
employees like canteen, overtime allowance and so on. It also has a visitor’s hall where the
students and different visitors are invited as well as welcomed to visit the dairy, has been
constantly serving the need of its valued consumer from the beginning. The achievement is
that, supplies its product covering almost all parts of eastern Nepal.

Objectives of the company

The main objective of the company are as below:

1. To provide guaranteed market for milk, to the rural farmers with reasonable price.
2. To provide quality milk and milk products to urban consumers.
3. To develop well organized milk collection system to meet increasing demands for
pasteurized milk and milk products.
4. To develop an organized market system for milk products in urban areas.

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Management

Organization name : Nepal Multipurpose Co-operative Society

Factory name : NMC Dairy Industry
Address : Mechinagar -08, Itavatta, Jhapa
Established year : 2072 BS
Nature of Ownership : Co-operative
Total area : 5 kattha

Capital Investment

NMC Dairy Industry has been supported financially by NMC. The capital investment is about
12 crores.

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
according to the requisition. The raw materials like chemicals, packing materials sugar, color,
stabilizer etc. that are required in the factory are demanded by the factory to the store
according to the need. The store demand good on the basis of the demand made by the factory
to the administrative section. They in turn order these inventories directly or through tender.
Transaction and recording of inventories are done through store.

Benefits and facilities

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 - Transportation facilities
- Yearly uniform allowance is given to each employee.

- Jackets, boots, gloves are given to worker working in different section like cold
stores, washing and processing section.

- Salary incentives are given once a year for each employee.

- Well managed canteen, first aid facilities.

- Quarter facilities for General Manager and Production Manager.

2. Raw Milk Collection

NMC Dairy purchases milk from various collection centres, dairies, cooperatives from
different places of Jhapa district. Not only from the large collection centres, dairy collects
milk from local farmers too. Transportation is done by means of 4 wheeler TATA pickup
carriers. Collection from local vendors is about 10,000 ltrs in average. Milk is inspected for
acidity, fat, snf, adulteration during receival.

Some major collection centres with the volume of milk supplied can be figured as below:

S.N. Name of collection centre Location Average volume of Collection

milk supplied in ltrs interval
1. Triveni milk collection centre Maharanijhoda 1200 Daily
2. Hatemalo cooperative organization Dharampur 700 Daily
3. Lagansil cooperative organization Lakhanpur 400 Daily
4. Ashirbaad chilling centre Sanischare 500 Daily
5. Kichakbath cooperative organization Pritvinagar 500 2 days
6. Shantinagar chilling centre Buddha shanti 650 Daily
7. Sarnamati chilling centre Sarnamati 1200 Daily
8. Karna Naina milk producer Harchana 1300 Daily

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9. Goldhap chilling centre Goldhap 600 Daily
10. G2G dairy Dharampur 400 2 days

11. New sulav chilling centre Surunga 500 Daily

12. Hadiya Majhuwa dairy Budhabare 300 2 days
13. Neupane dairy Dhaijan 150 2 days

14. Simalchowk chilling centre Shani Arjun 350 Daily

15. Boudhamode chilling centre Boudhamode 350 2 days

16. Dudhe chilling centre Dudhe 180 Daily

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Raw milk analysis
Platform test is performed for raw milk during receival. This test involves:

1. Acidity 6. CLR
2. pH 7. Alcohol test

3. Temperature 8. COB Test

4. Fat 9. Sensory evaluation
5. SNF 10. Adulteration Test ( Peroxide test, sugar test etc)

3. Product Profile:
NMC Dairy Industry is the leading manufacturer of various products like standardized
pasteurized milk, ice cream, yoghurt, cream, paneer, butter, rasbari, Peda, khoa and many
other sweets. Products can be listed as below:
1. Pasteurized Standardized milk
2. Cup yoghurt
3. Cup dahi
4. Pouch dahi
5. Ice – cream
6. Paneer
7. Nauni
8. Mohi
9. Peda
10. Rasbari

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 11. Khoa

4. Manufacturing details

4.1 Manufacturing Details of standard milk:

Milk receiving
Milk testing:
Organoleptic test: taste, smell, color, foreign
material
Physical/Chemical: COB, alcohol, acidity, fat,
SNF, CLR, temperature, adulteration test

Filtration

Chilling vat (4-5 ˚C)

Check for batch standardization

Run drum

Filter

Centrifugal pump

Plate heat exchanger for chilling (0-4 ˚C)

Standardization

Filter

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 Float balance tank

Centrifugal pump

Pasteurization at 80 ˚C

Holding section(15 sec)

Flow diversion valve

( If pasteurization temperature is not reached, air pressure forces valve to open and the milk
goes back for pasteurization)

Homogenizer (200 psi pressure)

Pasteurized milk storage tank

Filling machines (24pkts/crate)

Cold storage

Dispatch

Fig: Process flow chart for manufacturing of standard pasteurized milk

Potential Hazards
A) Physical Hazards
Hair, sand particles, dry leaves, dirt, dust, flies, rodents etc.
B) Chemical Hazards
Nitric acid, caustic soda, detergents, satol,
C) Biological Hazards
Brucella, Mycobacterium, Salmonella, Staphylococcus, Listeria monocytogenes,
Bacillus spp.

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4.2 Manufacturing of cream:

Milk receiving

Preheating (40° C)

Cream separating

Pasteurization (85°C/2-3sec)

Cooling(5°C)

Storing

Fig: flowsheet for cream separation

4.3 Manufacturing details of dahi

Raw milk reception

Standardization of milk
(Fat, SNF)

Heating of milk (45°C)

Addition of SMP

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 Addition of required amount of sugar (60°C)

Elevating temperature to 85-90˚C and holding for ½ hrs

Cooling to 45-47˚C & Culture addition (DVS culture- 50U/500L)

Agitation

Filling in cups

Incubating at 45˚C for 4 hrs until the curd is set

Storing in cold room at 4˚C

Dispatching

Fig: Process flow chart for manufacturing of yoghurt

Potential Hazards
A) Physical Hazards
Hair, dirt, dust, flies, rodents etc.
B) Chemical Hazards
Nitric acid, caustic soda, detergents
C) Biological Hazards
Brucella, Mycobacterium, Salmonella, Staphylococcus, Listeria monocytogenes,
Bacillus spp.
Note:Yoghurt, Cup dahi, Pouch dahi differs in total solid contents.

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4.4 Manufacturing details of ice cream

Pasteurized milk/Standard milk

Heating to 40-45 ˚C

Adding SMP at 45-50 ˚C

Sugar and stabilizer addition at 50-60 ˚C

Addition of cream) at 60-65 ˚C

Pasteurization at 82 ˚C for 15 sec (72 ˚C for 15 mins or equivalent treatment)

Homogenization at 65-70 ˚C

Chilling (4-8 ˚C)

Ageing the mix in insulated vat for overnight (24 hrs.) at 4˚C

Standardization (fat, TS, Protein, Acidity)

Adding color and flavor

Churning:
Freezing and whipping the mix in a continuous freezer (-4 to -6 ˚C)

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 Filling in ice cream cups or tubs

Sampling
Physical: Texture, Organoleptic,
sensory , over run

Transferring to hardening tunnel (-25 to -35 ˚C)

Shifting to cold storage (-18 to -20 ˚C)

Dispatching in refrigeration cold chain at -18 ˚C for sales

Fig: Process flow chart for manufacturing of ice cream

Potential Hazards
A) Biological Hazards
1.Brucella, Pseudomonas
B) Chemical Hazards
Nitric acid, caustic soda, detergents,
C) Physical Hazards
Hair, sand particles, dirt, dust, flies, rodents

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4.5 Manufacturing of paneer

Whole milk (min 5% fat, 8% SNF)

Heating at 85-90 ˚C for 20 min

Cooling to 76 ˚C

Adding citric acid and calcium chloride with slow agitation

Coagulation

Tempering for 5-10 min

Separating casein from whey by filtering through muslin cloth

Pressing the casein in molds for 20-30 min

(3 times the weight of casein)

Molding
Dipping in chilled water (4-5 ˚C) for 1 hour
With or without salt

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 Leaving overnight in cold open air

Cutting to required size and weight

Vacuum packaging in polythene packs

Storing in cold room after dispatch

Fig: process flow chart for manufacturing of paneer

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4.6 Manufacturing details of Nauni

Milk (3% fat)

Cream separation
Raw skim milk

Raw cream

Pasteurization

Ageing

Churning
Butter milk
Butter granules

Draining and washing

Raw nauni

Weighing and packaging

Storage and dispatch

Fig: Preparation of Nauni

Note: Buttermilk is standardized and supplied as NMC mohi.

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4.6 Manufacturing of Raswari
Milk

Heating to 80 ˚C

Cooling to 55-60 ˚C

Adding citric acid for coagulation

Standing for 10-15 min

Filtering the coagulum using muslin cloth

Hanging the chena mass until no water drips from the mass

Fresh chena

Mixing and kneading into dough (to give fine and smooth appearance)
in working table

Dividing the dough into 20-25 gm pieces

Rolling the pieces between the palms to form spherical balls

(Balls must be smooth and free from cracks)

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 Cooking in sugar syrup for 20-25 min
(Water: sugar = 2:1)

Texture stabilizing in hot water for 5-10 min

Transferring to sugar syrup of 50-60 ˚Bx

Cooling to 10 ˚C

Packaging

Storing and marketing

Fig: Process flow chart for manufacturing of raswari

5. Packaging Materials:
Packaging material is supplied by the supplier in Birgunj.

5.1 Polyethene pack

For milk polyethene film made from virgin food grade LDPE film is used and green
color printing is used as designed by NMC dairy. Polyethene packs are used for paneer
and butter also.

5.2 Plastic crates

Green colored plastic crates made from HDPE are used for milk pouches.Each crate has
capacity of 24 milk pouches.
For the yoghurt cups blue colored HDPE crates are used.each crate stores 24 cups of

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 2000ml and 6 cups of both 500ml and 1l.

5.3 Plastic cups

Different sized plastic cups are used for yoghurt,dahi and ice-creams. 1000ml, 500ml,
200ml cups are used for yoghurt and dahi. 50ml, 100ml and 500ml cups are used for
Ice-cream. Cups are provided with plastic lids. Filled ice-creams are then arranged in
steel trays.

6. Analysis performed

6.1. Determination of Fat in Milk

Principle

When sulphuric acid is added to milk the proteins will be digested thus destroying the
membrane of the fat globules. The free fat is released. The fat remains in liquid due to the
heat produced and during centrifugation the fat being lighter will be separated on top of the
solution. Addition of the amyl alcohol has the function of separating fat from other
components.

Procedure
 10ml of Gerber Sulphuric acid was measured into the clean butyrometer.
 10.75ml of the milk was pipette out and transferred carefully into the butyrometer
without allowing it to mix with the acid.
 1ml of the amyl alcohol was taken in the butyrometer.
 The stopper was tightened and then mixed by shaking.
 It was kept for 5min in water bath at 65 ˚C +2 ˚C in order to fully dissolve the casein
particles.
 It was then centrifuged in Gerber centrifuge at 1100 rpm for 4-5mins and again kept in
water bath for 5mins.
 Observed for the clear fat layer in the label of the butyrometer.

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6.2. Determination of Acidity of the milk
Principle
The amount of acid developed in the milk is expressed as % of lactic acid. Milk have pH 6.8-
7.2 but the presence of LAB converts lactose into Lactic acid and thus acidity develops.

Procedure
1. 10 milk is taken through the pippete and poured in the beaker
2. 1-3 drops of phenolphthalein is added
3. It is titrated against 0.1 N NaoH.

Acidity=( ml of alkali consumed * 0.09) %

6.3 Determination of solid not fat

It is the amount of solid remained after fat removal. Higher the concentration of
lactose higher will be the corrected lactometer reading(CLR) and higher will be
the SNF.
SNF= (CLR reading + Fat + 2 )/4

6.4 Determination of FFA content in nauni

Principle

Free fatty acids are readily soluble in rectified spirit or absolute alcohol. A suitable amount of
oil is therefore mixed with neutralized rectified spirit to extract free fatty acids and the amount
of the latter calculated by titrating with standard NaOH or KOH using phenolphthalein
indicator. To facilitate extraction,the mixture may be warmed to about 70°C and swirled
vigorously.

Procedure
1. Weigh about 5gm of sample in conocal flask.
2. Add 50ml neutral alcohol
3. Add 2-3 drop phenolpthalein indiicator
4. Swirl the contents and place flask on the hot plate.
5. Warm the mixture to about 70°C and swirl well.
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6. Titrate with 0.1N NaOH to persistant pink color.

Calculation

Titer value × 2.82

% FFA = %
sample weight

7. Tests for finished product

Product Physico-chemical test Microbial test Sensory test

Standard milk Fat, SNF, TS, acidity Flavor, taste, appearance

Yoghurt Acidity, TS Flavor, taste, appearance

Dahi Acidity, TS Flavor, taste, appearance

Mohi Acidity, TS Flavor, taste, appearance

Paneer Fat, moisture, SNF Flavor, taste, appearance

Nauni FAT, FFA Flavor, taste, appearance

Cream Fat Taste, smell

Rasbari Fat, moisture, Taste, smell

average weight
Peda Fat, TS Taste, smell

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In line quality control:
1. Standard milk production line

 Milk samples are sent to lab and are inspected for fat content, acidity and SNF to
meet the standards.
 During filling weight of milk pouches are continuously observed and machines are
adjusted according to requirement.
 Pouches are also examined for proper sealing and leakages.
 Pasteurization and cooling time, temperature are checked frequently.
 Pipelines, vats and tanks are cleaned in place (CIP) after processing each lot.
 Records are kept for each parameters.

2. Ghee production line

 Over and under filling of ghee packets and their proper sealing are checked.

3. Ice- cream production line

 Sesory evaluation is done

 Average weight of ice-cream with cups are measured

4. Paneer production line

 Time and temperature is observed during heating and clotting.
 During weighing weights of paneer are properly maintained.
 Proper sealing of vacuum packagedpackets are monitored.
 Finished product are inspected in lab.

5. Yoghurt production line

 Amount of ingredients, pasteurization time and temperature, sanitation is
maintained.
 Time and temperature for culture addition, incubation and cooling are properly
maintained.

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 8. Storage

Storage conditions for raw materials:

First in first out (FIFO) system is followed for all materials in NMC.

 Raw milk is stored in insulated tank at temperature of 4°C.

 SMP, color, flavors are stored at room temperature.
 Culture are maintained at -4°C and finished products are stored in cold
store.

Storage condition

Standard milk : 4-5°C

Yoghurt : 4-5°C
Paneer : 4-5°C
Ghee : 4-5°C
Ice-cream : -18 to -20°C

Average storage period of finished product before dispatch

Yoghurt : max 3 days

Paneer : 1-2 days
Ghee : 1-8 days
Ice-cream : 1-2 days
Standard milk : 1-2 days

9. Sources of contamination in dairy and dairy products:

a. From cow itself

During milking microorganism can enter the milk through skin of the teats which are
often contaminated by dungs, soil, dust, flakes of skin, hairs, etc. Several types of
microorganism can contaminate the milk like coliforms, faecal Streptococci, other
intestinal bacteria, spores and yeasts and molds.

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b. Soil,manure and dust;

All these contaminants can reach the milk and increase the counts.Moreover,the spores of
bacteria,yeasts and molds also occur in air.

c. From the transportation tanks and manufacturing process:

The other sources of contamination includes tanker, trucks, transfer pipes, sampling utensils,
equipment at the milk plant and other milk products processing plants. Pipelines, vats, tanks,
pumps, valve, separator, clarifier, homogenizer, cooler.
Stirrers and filler may serve as main possible sources for bacteria. The level of contamination
from each of these sources depends on cleaning and sanitizing methods.in addition, the
employees, particularly their hands and arms, are the possible sources of contamination and
pathogens. The packaging materials are also the main sources of contamination. The methods
of production, handling,
Storage and manufacture are also main sources of contamination.

d. Water used:

Tap water and surface water also contain many microorganism, including human pathogens,
and it must not be used for cleaning and rinsing.Pseudomonas, Achromobacter,
Flavobacterium and Alcaligens spp, are often occurred in contaminated water.

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 10. Important features of :

1. Generator
There are two generator to meet the required power. Generator requires about 45ltr/hr of
diesel.

Capacity 82.5 KW Capacity 200KW

Voltage 440V Voltage 440V

Frequency 50Hz Frequency 50Hz

RPM 1500 RPM 1500

Manufacturer name: Kirloskar Manufacturer name: Kirloskar

2. Boiler

One water tube boiler is used.

Capacity : 8kg/hr

volume : 2200-2500 ltr

Fuel : wood

Water level : 150

Temperature : min 145 °C, max 160°C

3. Transformer

Step down transformer is used which reduces the 11000 volt input to 440 volt output .
3 phase line used.

Frequency : 50Hz
Manufacturer’s name : Neek

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 4.Compressed air
Requirement: clean, oil free, dry, odorless and particularly sterilw uses in dairy plant.
 In pneumatically controlled automatic system.
 Powering the actuators in some machines such as filling machines.
 Emptying product from pipes.
 Agitation in storage tank.
 Compressed air tools to the workshop.

5. Pumps

Generally centrifugal pumps are used in dairy plant.

It is not self –priming hence the suction line and the pump casing must be filled with
liquid before it gives rapid rotary motion to a mass of water contained in the
surrounding case, centrifugal force forces the water out of the case through the
discharge outlet. The vacuum thus created makes available atmospheric pressure to
force in motor water. Centrifugal pump can be used to handle a wide variety of liquid
including suspensions, provided the viscosity is not too high.

6. Homogenizer

Homogenization is done to breakdown the fat globules into smaller globules

uniformly dispersed in the milk.
Done by two methods:
a) Single stage homogenization
b) Two stage homogenization

11. Cleaning in places (CIP):

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

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11.1 CIP Flow Chart

Running of hot water at 80 ˚C

Flushing up to outlet covering entire required area of pipe line and vats

Passing caustic detergents (1% concentration) through pipelines

Passing it subsequently to chiller, holding tubes,

Storage vats, batch filling machines

Either draining or re circulating it to caustic tank

Note
 Whole processing plant pipelines are cleaned with hot water and caustic solution twice
daily- once before starting operation and then after completion of all operations for the
day.
 Circulating with nitric acid solution is done only once a week.
 Milk storage tanks are cleaned with hot water and caustic solution every time they are
emptied.

12. Conclusions:

45 days of in plant at NMC Dairy Industry provided me the great opportunity to utilize the
theoretical knowledge gained in totally practical way. During this period I developed the
confidence to work in the food industries in systematic way. It was really such a great

27
pleasure to get linked with the production as well as quality control system inside the
industry. After this training following conclusions were made:-
 Quality was maintained
 Hygienic condition was maintained
 Skilled manpower was maintained
 Good disposal of wastage
 Well-equipped laboratory
 Good packaging material were used which gives good preservation to product.

13. Recommendations:

As in dairy industry hygiene and cleanliness is a key to keep the raw materials and
product clean,safe and quality, Many hygienic condition should be brought in practices:-

 Workers handling the products should be provided with gloves and masks as their spit
are directly passed to the products.
 CCP(critical control point) should be applied separately in every process that are
hazardous, of every products and control should be done.
 Training and information to the workers about different hazards should be conducted.
 Temperature reading was found to be not working as it is very important parameter
for quality and volume reading is not found in any of the milk storage tanks which is
creating problems in milk stocks.
 Only the trained person and authorized person should be given permission to enter to
QC lab and should be expanded.
 Dairy plant consumes large quantity of water for various purposes such as cleaning,
cooling, steam generation and also in processing, which must be of the highest quality,
exceeding the requirements for acceptable drinking water.
 The acid value and peroxide value of ghee can be checked for rancidity case.
 Coliform, Bacillus cereus and B.subtilis should be checked as they spoil pasteurized
milk by sweet curdling, a bad off flavor,or clumps of fat globules.
 The spoilage microorganism in raw milk like coliforms, mesophilic lactic acid
bacteria and psychrotrophsare inactivated by pasteurization but as the heat resistant

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 like Micrococci, some thermophilic Streptococci are not killedit should also be
checked.
 In dahi coliform count, yeasts and mold count can be done.
 There should be consistency in the weight of milk pouch and other products too.
 Mouth pipetting should be avoided

ANNEX 1
Production machinery at NMC
1. Standard milk machinery

Item No. of items Capacity Manufacturer’s name

PHE(milk ) 2 3000ltr/hr Repute
Filling machine 2 2760pkt/hr Nichrome

Homogenizer 1 3000ltr/hr Bertoli

Pasteurizer 1 3000ltr/hr Repute

2. Cream production machinery

Item No.of items Capacity Manufacturer’s name

PHE(milk) 2 3000ltr/hr Repute
Separator 1 3000ltr/hr Tetra

4. Yoghurt

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Item No. of machinery Capacity Manufacturer’s name
Continuous 1 1000ltr/hr Repute
pasteurizer

4. Ghee production plant

Item No. of item Capacity Manifacturer’s name

Butter churner 1 200ltr Repute

5. Ice-cream
Item No. of item Capacity Manufacturer
Batch pasteurizer 1 100ltr/hr Goma
PHE 1 100ltr/hr Goma
Ageing vat 1 100ltr/hr Goma
Filling machine 1 55ltr/hr Goma
Hardening tunnel 1 100ltr Goma

ANNEX 2
Organizational chart

NMC working committee

Dairy business community

Managing director

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QC Account Section Marketing Administration Production Store

Collection Marketing manager production manager store keeper

And chilling centre
Production helpers
Sales man driver operator

Layout of QC lab:

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 Basin Burner Sample receiving

Glasswares
Hot air oven
Titration stand

Chemicals

Water bath

Fridge
Weight balance Gerber centrifuge Entrance

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