Reading Material for

Curd (dahi) Production

Under PMFME Scheme

AATMANIRBHAR BHARAT

National Institute of Food Technology Entrepreneurship and Management

Deemed to be University (De-novo Category) under Section 3 of the UGC Act, 1956
An Autonomous Institution under Ministry of Food Processing Industries, Government of India
Plot no 97, Sector 56, HSIIDC, Industrial Estate, Kundli, Sonepat, Haryana – 131028
Website: www.niftem.ac.in, Email: [email protected], Contact No. 0130-2281089
PMFME – Curd (Dahi) Making

Contents

Chapter – 1: Raw Material

1.1 Introduction…………………………………………………………………………………04
1.2 Dairy Industry in India………………………………………………………………….04
1.3 Insight on value-added product…………………………………………………….05
1.4 Export-import opportunities…………………………………………………………05
1.5 Key deterrents to the growth of the market…………………………………..05
1.6 Need for Processing Milk………………………………………………………………06
1.7 Composition of Milk……………………………………………………………………...06
1.8 Nutritional Value of Milk……………………………………………………………….06

Chapter – 2: Processing and Machinery

2.1 Introduction……..………………….……………………………………………….……..……….08
2.2 Current status of dahi industry in India..……………………………………..………….08
2.3 Compositional standards of dahi .........…………………………….…………………..….09
2.4 List of machineries used for curd processing.........…………….…………………..….09
2.5 Dahi Processing Flow Chart (Traditional Method) ………………………….....…...10
2.6 Dahi Processing Flow Chart (Industrial Method) ..……………........…………...…….10
2.7 Standard operating procedures (sop’s) for dahi manufacturing……..............…11
2.8 Common defects in dahi .……………………………………………………………..............…12
Chapter – 3: Packaging
3.1 Packing material for dahi……………………......................................………………………13

Chapter – 4: Food Safety Regulations and Standards

4.1 Registration and licensing…………………………………………………………………….15
4.2 Hygiene, sanitary and good manufacturing practices (GMP)…………………...17
4.3 Packaging and labelling………………………………………………………………………….20
4.4 Coding and labelling of packing material…………………………………………………21
4.5 Exemption from labelling requirement…….................................................................22
4.6 Date of manufacturing or packing…………………………………………………………..22
4.7 Documentation and record keeping………………………………………………………..23
4.8 How to keep record………………………………………………………………………………..23

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Chapter – 5: Cleaning, CIP and Effluent Treatment

5.1 Tanker washing…………………………………………………….………………………………..24
5.2 Crate washing……………………………………………………………………………………..24
5.3 CIP of raw milk tanks/multipurpose vat etc………………………………………….24
5.4 Effluent Treatment Plant……………………………………………………………………..25
5.5 Plant performance and monitoring……………………………………………………….25
5.6 Environmental Management System: Implementation and operation……..27

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Chapter – 1
Raw Material
1.1 Introduction
Milk, liquid secreted by the mammary glands of female mammals to nourish their young
for a period beginning immediately after birth. The milk of domesticated animals is also an
important food source for humans, either as a fresh fluid or processed into a number of dairy
products such as butter and cheese (https://www.britannica.com). Milk is a nutritious choice
as it provides nine essential nutrients our body needs. Milk contains essential nutrients like
high-quality protein, calcium, vitamin D and more. These nutrients help our bodies function
properly. For example: Protein helps build and repair muscle tissue Calcium and vitamin D
helps build and maintain strong bones and teeth Milk also contains B vitamins, which can
help your body convert food into energy.

1.2 Dairy Industry in India

India is leading milk producing country in the world, accounting for 19 percent of the global
market share and expected to grow at compound annual growth rate (CAGR) of 14.8%
between FY 2018 – 2023. As per fiscal year 2019, milk production in India amounted to
about 187 million metric tons. As per FY – 2018, around 81% of the Indian dairy and milk
processing market comes under unorganized sector, where milk is processed in unhygienic
infrastructure, which affects the overall quality of milk and milk-based products.
Consumption patterns of liquid milk at the farm level and less infrastructure for processing is
the main reason for low value addition of milk. The demand for value added products
especially traditional dairy products is increasing day by day and the dairy industry of the
country is trying to meet the present demand.

Uttar Pradesh, Rajasthan and Gujarat are the major milk producing states in India. Uttar
Pradesh is the largest milk-producing state, as it has the highest buffalo population and the
second-highest cattle population in the country. Majority of the rural population in this state
is engaged in livestock nurture and dairy farming. Gujarat holds several cooperative dairy
unions, milk cooperative societies and private dairy plants, which play vital roles in the
production of milk and milk-based products in the state.

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1.3 Insight on value-added product

Apart from processed liquid milk, Indian dairy and milk processing industry generates
revenue from several value-added products such as butter, curd, paneer, ghee, whey,
flavoured milk, ultra-high temperature (UHT) milk, cheese, yogurt, dairy whitener and milk
powder. During the FY 2016 – 2020, the market size of dairy ingredients is expected to grow
by around 14%.

1.4 Export-import opportunities

The export of dairy products from India has increased to countries like Bhutan, Afghanistan,
Canada, Egypt, and the United Arab Emirates. India has also imported a significant number
of dairy products from countries like France, New Zealand, Ireland, France, Ukraine, and
Italy.

1.5 Key deterrents to the growth of the market

Despite having a significant livestock base of milch animals, India lacks in terms of good
processing facility and availability of cold storages which results in wastage of dairy output.
Lack of sufficient storage facilities and inefficient distribution channels are hampering the
growth of the Indian dairy and milk processing industry.

Sufficient quantity and good quality of feed and fodder are required for proper animal rearing
and milk production. Improper droughts and flood management affect the production of
fodder in India. Deficiency of proper feed and fodder for milch animals, due to high usage of
agricultural crop residues by producers of fibreboard, paper, and liquid fuels, affect its
availability for dairy production and milk processing.

Dairy marketing channels in India

Reference: FAO

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1.6 Need for Processing Milk

Milk is considered wholesome food mainly because of its high nutritive value. It has to be
processed to;

• Increase the shelf life, because it is highly perishable.

• Prepare value added products like peda, dahi, cheese, paneer, butter, ghee, AMF,
flavoured milk, cheese, and yogurt, dairy whitener, milk powder etc. and many more
dairy based products, for a good health.
• Make business out of it, create job opportunities, consequently building financially
strong Nation.

1.7 Composition of Milk

Milk composition varies with species, breed (Holstein, Jersey), feed, and the stage of
lactation. As per FSSAI, “Milk is a whole, fresh, clean lacteal secretion obtained by complete
milking of one or more healthy milch animals excluding that obtained within 15 days before
calving or 5 days after calving. Market milk must possess the pre-determined percentage of
milk fat and SNF (Solid Not Fat).”

Milk of different classes and types must conform to the standards laid down by FSSAI.
Mixed milk means a combination of the milk from cow and buffalo or any other milch
animal. The combination also should at par with FSSAI standards.

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1.8 Nutritional Value of Milk

Table: Nutritional values of milk

Nutritional Factor Description Energy Value
Protein Milk protein is casein, a high-quality protein. All 4.1 kCal/g
essential amino acids are present in Milk.
Minerals Milk contains phosphorus and calcium.
Vitamins Milk contains vitamins A, D, thiamine, and riboflavin.
Fat Milk fat is responsible of good flavor and physical 9.3 kCal/g
properties. The fat content in cow milk is generally
from 3.5 to 4.5 %
Lactose Lactose is the sugar component of milk and it supply 4.1 kCal/g
energy.

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Chapter – 2
Processing and Machinery
2.1 Introduction
Dahi is a set-type fermented dairy product originated in the Indian Subcontinent. Dahi is the
well-known product since from ancient time and misti dahi is popular in eastern region.
Consumption of fermented milk products is associated with several types of human health
benefits partly because of their content of lactic acid bacteria.

Dahi has valuable therapeutic properties and helps in curing gastrointestinal disorders. Dahi
added with probiotic bacteria enhances its health benefits such as immune enhancement,
blood pressure reduction, antiatherogenic effect, antidiabetic effect, anticarcinogenic effect,
antioxidative effect and curing of gastrointestinal disorders.

Characteristics FSSR (2011) BIS

Acidity % lactic acid - 0.6 - 0.8
Total Plate count Not more than 1000000/g -
Coliform count 10 per g max 10 per g max
Escherechia coli Absent in 1g -
Salmonella Absent in 25g -
Shigella Absent in 25g -
Stephylococcus aurius Not more than 100/g -
Yeast and Mould 100 per g max 100 per g max
Anaerobic spore Absent in 1g -
Listeria monocytogenes Absent in 1g -
Phosphatase test - Negative
Other requirements It should have the same minimum Dahi shall conform to the
percentage of fat and SNF as the milk requirements of milk fat
from which it is prepared. If no and MSNF, as laid down
standards declared then standards in FSSR, 2011
prescribed for dahi from buffalo milk
shall apply

2.2 Current status of dahi industry in India

About 9% of the total milk produced in India is converted to fermented milk products.

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Dahi accounts for around 90% of the total cultured milk products produced in India
(including both organised and unorganised sectors). Apart from local confectioner, all milk
co-operative and private dairies are producing and marketing dahi and dahi based products.
Probiotic dahi is a regular curd with added advantage of unique probiotic cultures like
Lactobacillus acidophilus or Bifidobacterium bifidum. As per a report published with a title
“India Probiotics Market - Forecasts from 2020 to 2025”, India Probiotics Market is expected
to grow at a compound annual growth rate of 13.56% over the forecast period to reach a
market size of US$961.856 million in 2025 from US$448.456 million in 2019.

2.3 Compositional standards of dahi

The product shall conform to the compositional specifications provided in the table below:

Components Whole milk Dahi (%) Skim milk Dahi (%)

Water 85-88 90-91

Fat 5–8 0.05 - 0.1

Protein 3.2-3.4 3.3-3.5

Lactose 4.6-5.2 4.7-5.3

Lactic acid 0.5-1.1 0.5-1.1

Ash 0.7-0.75 0.7-0.75

2.4 List of machineries used for curd processing:

The selection of equipment is totally depending on the scale of production, final product
storage capacity and the final product pack type and size. List of major equipment is
presented below:
i) Raw milk storage tank

ii) Milk pasteurizer and homogenizer

iii) Pasteurized milk storage tank

iv) Curd setting tank (after culture addition)

v) Cup Filling and Sealing Machine (100/200/400gm – 25 cups per minute)

vi) Curd Incubation Room

vii) Cold room

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2.5 Dahi Processing Flow Chart (Traditional Method)

Raw milk (antibiotic –ve, protien: min 36%)

Stored in multipurpose VAT

Boil for 5 to 10 min

Cooled to room temperature

Added with previous day’s curd or buttermilk

Stirred and allowed to set undisturbed for overnight

Store at 4-50C In Cold Store till despatch

2.6 Dahi Processing Flow Chart (Industrial Method)

Raw milk (antibiotic –ve, protien: min 36%)

Process & stored in PMST

Standardization

Homogenization: 150/50 BAR two stages, Pasteurization: 950C, hold for 6 min, cooling to
40C

Pasteurized Dahi Milk Storage Tank

Transfer to inoculation tank through PHE for by heating milk to 420C

Inoculation: Culture addition at the recommended dosage rate0°C

Filling & sealing: in cups/ poly pouch/ matka & transfer cups in c. Box/ poly pouch in crate/
matka in crates

Incubate: 42 ±20C For 4-6 hours till pH is 4.7± 0.5

Blast cooling: As soon as pH is achieved, transfer to blast cold room with direct blowers for
faster cooling -achieve 420C to 100C in 3.5 - 4 hrs in cold room

Store at 4-50C In Cold Store till despatch

Dispatched in refrigerated trucks and vans maintaining a temperature of below 80C

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2.7 Standard operating procedures (sop’s) for dahi manufacturing

1. Raw Milk Reception: The Raw Milk received in tankers/food grade barrels is weighed
either in weighbridge or in weighing bowl Batch wise and subject to sampling & testing for
its parameter as per specified and defined procedures.

2. Filtration: The accepted milk is weighed and unloaded in the Dump Tank and Pumped
through a chiller after properly filtering, such milk is stored in the silos through the
previously cleaned, sterilized/ steamed pipe line, and silos act.

3. Chilling: Filtered milk is chilled through a chiller ensuring the temperature not more than
5 deg. Chilled milk is stored in the silos through the previously cleaned, sterilized/ steamed
pipe line, silos etc.

4. Standardization of Milk: Milk Pasteurization and Standardization of milk is planned as

per product requirement and fat & SNF is maintained.

5. Homogenization and Pasteurization: Homogenization of milk is done at 150/50 bar in

two stages and then Pasteurization at 950C by passing through automatic holding tube for 6
mins and cooling to 40C. Milk is then transferred to storage tank.

6. Inoculation and culture addition: Now transfer the milk to inoculation tank through PHE
for heating milk at 420C. Take appropriate quantity of milk so that filling is over in one hour.
Culture addition is done at recommended doses.

7. Filling and Sealing: Milk with culture is filled in required packing sizes and stacked in
trolleys.

8. Incubation: Trolleys then moved to incubation room maintained a temperature of 42±20C.

Incubation is done for 4 to 6 hours till pH of 4.7±0.5 is achieved.

9. Blast Cooling: As soon as pH is achieved, trolleys are transfer to blast cold room at zero
degree with direct blowers so that the product temperature of 100C is achieved within 3.5 to 4
hrs mins.

10. Cold Storage: After 3.5 - 4 hrs transfer the trolleys in cold storage under 50C till the time
of dispatch.

11. Dispatch: Product is dispatched in refrigerated trucks and vans maintaining a temperature
of below 50C.

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2.8 Common defects in dahi

Sl No. Defect Probable Cause Remedy
Flavor defects
1 Insufficient flavor Low citrate level in milk, Add 0.02 to 0.05% Sodium
citrate prior to mixing the
Low diacetyl content starter culture.
Cool rapidly after culturing
2 Oxidized flavor Copper contamination Avoid usage of copper
Exposure to fluorescent light utensils
Exposure to sunlight Protect product from direct
exposure to Sunlight/ UV
light
3 Yeast/cheesy Contaminating yeast growth Sanitation check
4 Rancid flavor Lipolytic activity Do not mix pasteurized and
raw dairy ingredients prior to
homogenization
5 High acid Addition of more culture, Optimum culture addition
Increased incubation time Blast cool the product
Use of sour milk immediately after optimum
pH is reached
Use good quality fresh milk
Body and textural defects
1 Weak body Insufficient heat treatment to Heat treatment should not be
the mix less than 85oC/30min
Too low milk SNF Homogenize the dahi mix
Severe agitation after prior to homogenization
fermentation Increase the MSNF content to
11% by adding Skim milk
powder
2 Grainy texture High acidity Rapidly cool the product to
Improper dispersion of Skim <5oC after attaining optimum
milk powder acidity
Use in line screen/filter
3 Syneresis Insufficient heat treatment to Heat treatment should not be
the mix less than 85oC/30min
Improper standardization and Increase the MSNF content to
too low milk SNF min. of 11% by adding Skim
Agitation/disturbances milk powder
during fermentation Do not disturb the cups
during fermentation
4 Ropiness Contamination of milk with Proper heat treatment of milk,
psychotropic Avoid cold storage of milk
microorganisms before
pasteurization/thermization
Culture
contamination/impure Use of pure culture
culture

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Chapter – 3
Packaging
3.1 Packaging material for dahi packing

Earthenware pot with a loose cover of glassine or greaseproof paper is generally used for the
traditional packaging of dahi and misti dahi.

Disadvantage of earthenware pot:

i) very heavy,

ii) easily breakable and

iii) product inside the earthenware pot develops shrinkage cracks because of oozing of
water to the atmosphere from pot .

At industrial level, injection moulded polystyrene and Polypropylene/ HIPS cups have been
used with aluminium foil based peelable lids. A shelf-life of about 10 days under
refrigeration condition may be achieved with this packaging material.

Advantage of injection moulded polystyrene and Polypropylene/ HIPS:

i) light in weight

ii) available in capacities of 200 grams and 400 grams and

iii) easy to handle and are hygienic

iv) can be painted, labelled, and designed with ease

v) low cost

vi) good impact resistance,

vii) excellent machinability and

LDPE pouches of 200ml, 500ml capacity and more is also used for the packing dahi.

Misti dahi is packed in food grade polystyrene and polypropylene cups in 100g, 200g pack
sizes. Various packaging machines of up to 400 cups/min speed are available to package
cultured dairy products in different sizes.

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Cup Filling Machines are used to pack Dahi in cups. Plastic cups either preformed, from a
film in the machine itself or readymade cups when used are placed in the stacker of the
machine.
Storage Conditions:
• Plain dahi was in good condition up to 3 days of storage period
• At refrigeration temperature plain dahi was suitable for consumption up to 12
days.
• The packaged product should be stored at <5°C for extended shelf life.

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Chapter – 4
Food Safety Regulations and Standards

4.1 Registration and Licensing of Food Business

All Food Business Operators in the country will be registered or licensed in accordance
with the procedures laid down
Registration of Petty Food Business
a. Every petty Food Business Operator shall register themselves with the Registering
Authority by submitting
b. An application for registration in Form A under Schedule 2 of these Regulations
along with a fee as provided in Schedule 3.
c. The petty food manufacturer shall follow the basic hygiene and safety requirements
provided in Part I of Schedule 4 of these Regulations and provide a self-attested
declaration of adherence to these requirements with the application in the format
provided in Annexure-1 under Schedule 2.
d. The Registering Authority shall consider the application and may either grant
registration or reject it with reasons to be recorded in writing or issue notice for
inspection, within 7 days of receipt of an application for registration.
e. In the event of an inspection being ordered, the registration shall be granted by the
Registering Authority after being satisfied with the safety, hygiene and sanitary
conditions of the premises as contained in Part II of Schedule 4 within a period of
30days.
f. If registration is not granted, or denied, or inspection not ordered within 7 days as
provided in above sub regulation (3) or no decision is communicated within 30 days
as provided in above sub regulation (4), the petty food manufacturer may start its
business, provided that it will be incumbent on the Food Business Operator to
complywith any improvement suggested by the Registering Authority even later.
g. Provided that registration shall not be refused without giving the applicant an
opportunity of being heard and for reasons to be recorded in writing.
h. The Registering Authority shall issue a registration certificate and a photo identity
card, which shall be displayed at a prominent place at all times within the premises or
vehicle or cart or any other place where the person carries on sale/manufacture of
food in case of Petty Food Business.

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i. The Registering Authority or any officer or agency specifically authorized for this
purpose shall carry out food safety inspection of the registered establishments at least
once in a year. Provided that a producer of milk who is a registered member of a dairy
Cooperative Society registered under Cooperative Societies Act and supplies or sells
the entire milk to the Society shall be exempted from this provision for registration.
4.2 Hygienic, Sanitary and Good Manufacturing Practices (GMP/GHP)
In addition to Part-II, the dairy establishment in which dairy-based food is being handled,
processed, manufactured, stored, distributed and ultimately sold by the food business
operator, and the persons handling them should conform to the sanitary and hygienic
requirement, food safety measures and other standard as specified below.

1. Sanitary requirements
a. Facilities for the hygienic handling and protection of raw materials and of non-packed
or non-wrapped dairy products during loading and unloading, transport & storing
including Bulk Milk cooling facilities.
b. Special watertight, non-corrodible containers to put raw materials or dairy products
intended for human consumption. Where such raw materials or dairy products are
removed through conduits, these shall be constructed and installed in such a way so as
to avoid any risk of contamination of other raw materials or dairy products;
c. A waste water disposal system which is hygienic and approved;
d. Facilities for cleaning & disinfecting of tanks used for transporting dairy products and
raw milk. These containers have to be cleaned after every use.
e. The occupier of a dairy establishment shall take appropriate measures to avoid cross-
contamination of dairy products in accordance with the cleaning program as specified
in point 9.1 of Part II.
f. Where a dairy establishment produces food stuffs containing dairy products together
with other ingredients, which have not undergone heat treatment or any other
treatment having equivalent effect, such dairy products and ingredients, shall be
stored separately to prevent cross-contamination.
g. The production of heat-treated milk or the manufacture of milk-based products, which
might pose a risk of contamination to other dairy products, shall be carried out in a
clearly separated working area.

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h. Equipment, containers and installations which come into contact with dairy products
or perishable raw materials used during production shall be cleaned and if necessary
disinfected according to a verified and documented cleaning programme.
i. Equipment, containers, instruments and installations which come in contact with
microbiologically stable dairy products and the rooms in which they are stored shall
be cleaned and disinfected according to a verified and documented. Food Safety
management programme drawn up by the owner/occupier of the dairy establishment.
j. Disinfectants and similar substances used shall be used in such a way that they do not
have any adverse effects on the machinery, equipment, raw materials and dairy
products kept at the dairy establishment. They shall be in clearly identifiable
containers bearing labels with instructions for their use and their use shall be followed
by thorough rinsing of such instruments and working equipment with potable water,
unless supplier's instructions indicate otherwise.
2. Personal hygiene requirements
a. The Food Business Operator shall employ those persons only in such an establishment
to work directly with and handle raw materials or dairy products if those persons have
proved to the occupier's satisfaction by means of a medical certificate, on recruitment,
that there is no medical impediment to their employment in that capacity.
b. Persons working directly with and handling raw materials or dairy products shall
maintain the highest standards of personal cleanliness at all times. In particular they
shall
• wear suitable, clean working clothes and headgear which completely encloses their
hair;
• Wash their hands at least each time work is resumed and whenever contamination of
their hands has occurred; e.g., after coughing / sneezing, visiting toilet, using
telephone, smoking etc.
• (Cover wounds to the skin with a suitable waterproof dressing. No person with injury
on hand, even with dressing, shall be placed in any product making/handling section.
• avoid certain hand habits - e.g., scratching nose, running finger through hair, rubbing
eyes, ears and mouth, scratching beard, scratching parts of bodies etc. that are
potentially hazardous when associated with handling dairy products, and might lead to
food contamination through the transfer of bacteria from the employee to product

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during its preparation. When unavoidable, hands should be effectively washed before
resuming work after such actions
3. Sanitary requirements for storage
a. Immediately after procuring, raw milk shall be placed in a clean place, which is
suitably equipped so as to prevent any kind of contamination.
b. The cans/ containers made up of mild steel metal and plastic material used for storage
and transportation of milk and milk products shall not be allowed.
c. If raw milk is brought to the dairy plant by a producer or farmer then it shall be
ensured that he brings it within four hours of milking and it shall be cooled as soon as
practicable to a temperature of 4ºC or lower and maintained at that temperature until
processed.
d. Where raw milk is collected daily from a producer, it shall be cooled immediately to a
temperature of 4ºC to 6ºC or lower and maintained at that temperature until
processed;
e. When the pasteurization process is completed, pasteurized milk shall be cooled
immediately to a temperature of 4ºC or lower. Subject to Paragraph 7 below, any
dairy product not intended to be stored at ambient temperature shall be cooled as
quickly as possible to the temperature established by the manufacturer of that product
as suitable to ensure its durability and thereafter stored at that temperature.
f. Where dairy products other than raw milk are stored under cooled conditions, their
storage temperatures shall be registered and the cooling rate shall be such that the
products reach the required temperature as quickly as possible.
g. The maximum temperature at which pasteurized milk may be stored until it leaves the
treatment establishment shall not exceed 5ºC.
4. Wrapping and packaging
a. The wrapping and packaging of dairy products shall take place under satisfactory
hygienic conditions and in rooms provided for that purpose.
b. The manufacture of dairy products and packaging operations may take place in the
same room if the following conditions are satisfied:
• The room shall be sufficiently large and equipped to ensure the hygiene of the
operations;
• the wrapping and packaging shall have been brought to the treatment or processing
establishment in protective cover in which they were placed immediately after

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manufacture and which protects the wrapping or packaging from any damage during
transport to the dairy establishment, and they shall have been stored there under
hygienic conditions in a room intended for that purpose;
• The rooms for storing the packaging material shall be free from vermin and from dust
which could constitute an unacceptable risk of contamination of the product and shall
be separated from rooms containing substances which might contaminate the
products. Packaging shall not be placed directly on the floor;
• packaging shall be assembled under hygienic conditions before being brought into the
room, except in the case of automatic assembly or packaging, provided that there is no
risk of contamination of the products;
• packaging shall be done without delay. It shall be handled by separate group of staff
having experience in handling and product wrapping and
• immediately after packaging, the dairy products shall be placed in the designated
rooms provided for storage under required temperature.
c. Bottling or filling of containers with heat-treated milk and milk product shall be
carried out hygienically.
d. Wrapping or packaging may not be re-used for dairy products, except where the
containers are of a type which may be re-used after thorough cleaning and
disinfecting.
e. Sealing shall be carried out in the establishment in which the last heat-treatment of
milk or liquid milk-based products have been carried out, immediately after filling, by
means of a sealing device which ensures that the milk is protected from any adverse
effects of external origin on its characteristic. The sealing device shall be so designed
that once the container has been opened, the evidence of opening remains clear and
easy to check.

4.3 Packaging and Labelling

The packaging design and materials shall provide protection for products in order to
prevent contamination, damage and accommodate required labelling as laid down under the
FSS Act and the Regulations there under. Only food grade packaging materials shall be used
as primary packaging material. Packaging materials like aluminium, tin and plastic shall
conform to the Indian standards as mentioned under the FSS Regulations from time to time.
The food packaging materials shall be inspected before use to avoid using damaged, defective
or contaminated packaging, which may lead to contamination of the product.

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• The wrapping and packaging of dairy products shall take place under satisfactory
hygienic conditions and in rooms provided for that purpose.
• The rooms for storing the packaging material shall be free from vermin and from dust
which could constitute an unacceptable risk of contamination of the product and shall
be separated from rooms containing substances which might contaminate the
products. Packaging shall not be placed directly on the floor.
• Packaging shall be done without delay followed by labelling. If it is not the case,
appropriate procedure shall be applied to ensure that no mix-ups or mislabelling could
occur. It shall be handled by separate group of staff having experience in handling and
product wrapping and immediately after packaging; the dairy products shall be placed
in the designated rooms provided for storage under required temperature.
• Packaging material/wrapping materials shall be protected from external
environment/contamination during transport and storage. Facilities shall be
established for safe and hygienic storage of packing materials at the dairy plant.”
• Wrapping or packaging may not be re-used for dairy products, except where the
containers are of a type which may be re-used after thorough cleaning and
disinfecting.
• “Packaging of milk and milk products shall be carried after processing. The packages
should be designed so as to ensure they are tamper proof and are not easily damaged
during general handling /operation. Once the packages are opened it should be easily
identifiable and cannot be duplicated against a fresh/unopened package”.
• The ink used for printing of primary food packaging should be of food grade quality.
This should comply with IS 15495 standards or other international standards for use
in food packaging and printing.
4.4 Coding and Labelling of Packaging Material
Fluid milk: The caps of the milk bottles /pouch/aseptic pack shall clearly indicate the nature
of the milk contained in them. The indication may be either in full or by abbreviation shown
below:
i) Buffalo milk may be denoted by the letter ‘B’.
ii) Cow milk may be denoted by the letter ‘C’
iii) Goat milk may be denoted by the letter ‘G’
iv) Standardized milk may be denoted by the letter ‘S’
v) Toned milk may be denoted by the letter ‘T’

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vi) Double toned milk may be denoted by the letter ‘DT’

vii) Skimmed milk may be denoted by the letter ‘K’
viii) Pasteurised milk may be denoted by the letter ‘P; followed by the class of milk.
For example, Pasteurised Buffalo milk shall bear the letters ‘PB ‘.
ix) Alternatively, suitable indicative colours of the packs/caps/bags shall be indicative of
the nature of milk contained in them, the classification of colours being displayed
at places where milk is sold\stored or exhibited for sale, provided that the same
had been simultaneously intimated to the concerned Designated Officer, and
information disseminated through the local media

4.5 Exemptions from labelling requirements

Where the surface area of the package is not more than 100 square centimetres, the label
of such package shall be exempted from the requirements of list of ingredients, Lot
Number or Batch Number or Code Number, nutritional information and instructions for
use, but this information shall be given on the wholesale packages or multi piece
packages, as the case may be.

1. The 'date of manufacture' or 'best before date' or 'expiry date' may not be required to
be mentioned on the package having surface area of less than 30 square centimetres
but this information shall be given on the wholesale packages or multi piece packages,
as the case may be;
2. In case of liquid products marketed in bottles, if such bottle is intended to be reused
for refilling, the requirement of list of ingredients shall be exempted, but the
nutritional information specified in regulation 2.2.2 (4) these regulations shall be
given on the label. Provided that in case of such glass bottles manufactured after
March 19, 2009, the list of ingredients and nutritional information shall be given on
the bottle.
3. “To make a fluid not below the composition of toned milk or skimmed milk (as the
case may be) with the contents of this package, add (here insert the number of parts)
of water by volume to one part by volume of this condensed milk or desiccated
(dried) milk”.
4. In case of food with shelf-life of not more than seven days, the 'date of manufacture'
may not be required to be mentioned on the label of packaged food articles, but the
'use by date' shall be mentioned on the label by the manufacturer or packer.

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5. In case of multi piece packages the particulars regarding list of ingredients, nutritional
information, Date of manufacture/ packing, best before, expiry date labelling of
irradiated food and, vegetarian logo/non vegetarian logo, may not be specified.

4.6 Date of manufacture or packing

The date, month and year in which the commodity is manufactured, packed or pre-packed,
shall be given on the label:

Provided that the month and the year of manufacture, packing or pre-packing shall be given if
the “Best Before Date” of the products is more than three months:

Provided further that in case any package contains commodity which has a short shelf life of
less than three months, the date, month and year in which the commodity is manufactured or
prepared or pre-packed shall be mentioned on the label.

Best Before and Use By Date

i) the month and year in capital letters upto which the product is best for
consumption, in the following manner, namely:

“BEST BEFORE ....... MONTHS AND YEAR

OR

“BEST BEFORE .......... MONTHS FROM PACKAGING

OR

“BEST BEFORE ............MONTHS FROM MANUFACTURE

(Note: — blank be filled up)

ii) In case of package or bottle containing sterilised or Ultra High Temperature treated
milk, soya milk, flavoured milk, any package containing bread, dhokla, bhelpuri,
pizza, doughnuts, khoa, paneer, or any uncanned package of fruits, vegetable,
meat, fish or any other like commodity, the declaration be made as follows

“BEST BEFORE ………DATE/MONTH/YEAR”

OR

“BEST BEFORE........DAYS FROM PACKAGING”

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OR

“BEST BEFORE ……..DAYS FROM MANUFACTURE”

Note:

(a) blanks be filled up

(b) Month and year may be used in numerals (c) Year may be given in two digits

(iii) On packages of Aspartame, instead of Best Before date, Use by date/recommended last
consumption date/expiry date shall be given, which shall not be more than three years from
the date of packing;

(iv) In case of infant milk substitute and infant foods instead of Best Before date, Use by date/
recommended last consumption date/expiry date shall be given, Provided further that the
declaration of best before date for consumption shall not be applicable

4.7 Documentation and Record Keeping

Every organization has to maintain records of raw material procurement, production
processes, and sales. This is to ensure that the business runs effectively and is profitable.
Listed below are some reasons why there is a need for documentation:

1. It gives detailed knowledge about running the business.

2. It helps to control product quality.
3. It helps to keep track of the money invested in the business.
4. It helps to identify the separate costs of raw material or product ingredients.
5. It helps to identify the production cost of a particular process.
6. It helps to make sure that all the quality assurance practices were followed
during the production.
7. It helps to make sure that the production equipment is running
smoothly/effectively.
8. It works as an evidence for legal procedures.
9. It helps to set an appropriate product price.
10. It helps to take corrective measures at the right time.

4.8 How to Keep Records?

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Every food processing organization follows a more or less similar way of keeping records.
Production records keep a log of the following:

• The quantity and type of raw materials received

• The quantity and type of ingredients used during processing
• The processing conditions in which production took place (e.g., the temperature set or
the air pressure applied)
• The product quality produced

Product quality can be maintained only when:

• The same quantity and quality of ingredients and raw materials are mixed in every
batch
• A standard formulation is used for every batch
• Standard process parameters are applied for every batch

Every batch of food is given a batch number. This number is recorded in:

• Stock control books (where raw material procurement is noted)

• Processing logbooks (where production process is noted)
• Product sales records (where sales and distribution are noted)

The batch number must correlate with the product code number, which is printed on labels.
This helps the processor to trace any fault found in a batch back to the raw material used or
the production process.

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Chapter – 5
Cleaning and CIP

5.1 Tanker Washing

The main objective of this unit is to clean the tankers properly after unloading or before
uploading milk or any other dairy ingredients to avoid microbial and bacterial growth.
Stepwise washing operation:
➢ Circulate Caustic solution for 15min. (1 – 1.5%) at 70 – 750C.
➢ Flush out Caustic with water.
➢ Circulate with hot water for 15min. (80 – 850C)
➢ Allow temperature to cool down
➢ Get QA clearance

5.2 Crate Washing:

Normally a semi-automatic crate washer is used for cleaning the crates. The washer
cleans the crates in stages
Solid waste removal – Manually
1. Pre-rinse
2. Hot water and caustic solution
3. Final rinsing

5.3 CIP of raw milk tank, multipurpose tank etc.

➢ Flush Silo with necessary water

➢ Clean (by brushing) the door of the manhole and sampling point with soap oil and
water.
➢ Circulate Caustic solution for 20min. (1 – 1.5%) at 70 – 750C.
➢ Flush out Caustic with water.
➢ Circulate with acid for 20min. (0.6 – 1.0%) at 60 – 650
➢ Circulate with hot water for 20min. (80 – 850C)
➢ Allow temperature to cool down

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Fig: A two station CIP Circuit(model)

5.4Effluent Treatment Plant (ETP)

ETP is a 24 hrs. continuous process. It takes hazardous outlet from all the process as inlet,
treat it in three stages (Primary, Secondary and Tertiary stage) to reach the environmental
standard. The outlets of the plant namely solid waste and treated water are respectively
disposed in field and used for irrigation purpose in plant to develop green belt.

Effluent Sources:
1. CIP: Caustic and Nitric Acid
2. Backwash: Water
3. Tanker wash: Caustic and Nitric Acid
4. Boiler: Water
5. Caret wash: Caustic

Stepwise description of ETP functioning:

1) Screen chamber: Raw effluent from the plant is received by screen chamber and
suspended particles are removed here.

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2) Collection and equalization tank: After the screening the effluent enters the collection
and equalization tank, where it is neutralized with hydrochloric acid and the effluent
is made homogeneous.
3) Holding tank: It only meant for storage when excess amount of effluent is discharged
from plant during CIP
4) Dissolved Air Floatation (DAF): The neutralized effluent from collection and
equalization tank is received here and aluminum sulphate (a non-ferric alum) is
added. The suspended and emulsified solids are separated here.
5) Buffer tank: It is an over flaw storage tank
6) Up blow Anaerobic Suspended Sludge Blanket (UASSB) Reactor (I&II): 12% to15%
of the total volume of this tank is filled with biomass. It receives the effluent from
DAF from the bottom of the tank. There are two types of bacteria present here.
a. Acetogenesis: - It converts the large chain molecule to small chain molecule and
produces amino acid.
b. Methenogenesis: - It converts to methane gas, and hence organic load decreases
7) Hopper bottom tank: It is just a tank to control the escaped microbes from UASSBR
and again recirculate it.
8) Aeration tank: In this tank aerobic microbes are developed
9) Lamella clarifier: It is used for solid settling purpose i.e., the solid liquid separation
takes place here
10) Secondary clarifier: Here the aerobic culture is settled and again circulated to aeration
tank to maintain the amount.
11) Treated water tank: Here the treated water from secondary clarifier or lamella clarifier
is collected.
5.5 Plant Performance and Monitoring:
➢ Carryout regular monitoring program involving maintenance of record and analysis of
effluent sample.
➢ ETP assistants have to collect samples at different stages of treatment system in
presence of ETP in-charge for analysis.
➢ ETP in-charge has to do the analysis and record the result also report the result to
EHS-engineer and EHS-officer. EHS-engineer and EHS-officer both will assess the
performance of the plant based on laboratory analysis report and instruct the ETP in-

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charge and assistants about the action to be taken in case of any deviation from
normal.
➢ The treated effluent has to be analyzed on daily basis and the results are recorded

5.6 Environmental Management System (EMS): Implementation and

operation:

2. Level-1: EMS manual; describes the core elements of the EMS and their
interactions. It outlines the structure of the document used in the EMS in line with-
ISO 14001-2004 manual also describe the procedures elaborately how various
requirements of ISO 14001-2004 are implemented.
3. Level-2: Documents; the filled formats which conveys the data that affects the
environment. Ex – Operational control process, environmental management
programs, emergency procedures, monitoring and management plans, training plan
etc.
4. Lavel-3: Formats; used for recording and conveying data effecting the environment

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