Hatsun agro private limited

BY ,
VARSHINI.S,
3rd YEAR B.VOC(DPT),
GANDHIGRAM RURAL INSTITUTE,
DINDIGUL.
Hatsun Agro Product limited is a dairy
company with business-to-farmer at well
as business-to-consumer operations.
Hatsun Agro Product (HAP) has a
production capacity close to 33 lakh
litres on average from nearly 4 lakh
farmers through its network of around
10000 milk banks, with bulk milk coolers
running entirely on thermal batteries.
HAP generates more than 95% of its
revenue is from sales of products to
retail consumers under brands.
Hatsun Agro Products (HAP) is primarily
engaged in the business of manufacture
and marketing of ice cream and milk and
dairy based products. The company sells its
products under the brands viz. Arun
Icecreams, Arokya Milk, Hatsun Curd,
Hatsun Paneer, Hatsun Ghee, Hatsun Dairy
Whitener and IBACO. The company
exports dairy ingredients to 38 countries
around the world - primarily in America,
the Middle East and South Asian markets.
Haxtun Foods was incorporated as a private limited company in March
1986, by R G Chandramohan. In April 1986, the company was admitted as
a partner in Chandramohan & Co, a partnership firm, promoted by the
same promoter. During the same month, Chandrmohan & Co was dissolved
and all the assets and liabilities of the firm vested with the company, except
the Arun brand name which was vested with R G Chandramohan. In 1987,
the company acquired the Arun brand name, subject to a payment of 1%
royalty on the company's gross ice cream sales turnover. The company
became a public limited company in August 1995.
Till April 1995, the company was carrying on its manufacturing activities. It
scrapped its manufacturing facilities at Tolgate unit, since the facilities
became old and outlived its utilities. The company has put up a 250-KVA
windmill for power generation. Hatsun came out with a public issue in
January 1996.

The name of the Company has been changed with the approval of the
Central Government from Hatsun Milk Food Limited to Hatsun Agro
Product Limited effective from 7 April 1998.The Company has
diversified its activities and entered into production and sale of Toor
Dhall and Urad Dhall under the brand name 'Apurva'.
Hatsun Milk Products Limited was merged with the Company with retrospective effect
from 1.4.98 vide order of high court dated 18.2.99. and the process of
amalgamation was completed on 26.2.99. Ajith Dairy Industries too merged with the
company. The company has also amalgamated Hatsun Foods Company Ltd. During
2000-2001 the company's second dairy plant was commissioned at Belgaum.

In 2007, Hatsun Agro Products (HAP) launched a new format of ice cream
parlour called Arun Unlimited Parlour'. In 2010, Hatsun Agro Products (HAP)
commissioned dairy plants at Madurai.
In 2012, Hatsun Agro Products (HAP) launched a new premium ice cream parlour
format called IBACO'. During the year, the company commissioned dairy plants at
Thalaivasal in Tamil Nadu, a milk processing plant at Honnali, near Davengere,
Karanataka and also commenced commercial production at its curd plant situated at
Vellichandai, Dharmapuri district in Tamil Nadu.

In 2013, Hatsun Agro Products (HAP) completed the acquisition of the assets of
a cattle feed plant from SKM Egg Products Export (India) Limited. In 2014,
Hatsun Agro Products (HAP) acquired dairy business of Jyothi Dairy Private
Limited. In 2015, Hatsun Agro Products (HAP) acquired a feed mill unit
belonging to VKS Farms Private Limited, Coimbatore.
 On 6 March 2017, Hatsun Agro Products (HAP) announced that it has

commissioned wind power plants with 24 MW capacity at Tuticorin district, Tamil

Nadu. The power generated from the plant will be used for captive consumption.

Hatsun Agro Products commissioned an automated packaging film unit, a

greenfield project at Wallajabad near Chennai and started its
commercial production in October 2017.

In June 2018, Hatsun Agro Products launched a rights issue of equity

shares for prepayment/repayment of borrowings availed by the
company. The rights issue was offered in the ratio of one share for
every 16 shares held on the record date. The issue was priced at Rs
555 per share.
1970- Company began its footprint with the introduction of Arun Icecreams

1978- Airst Arun milk parlour.

1986-M/s. Hatsun Foods Private Limited (HFPL) is incorporated as a
Private Limited Company. The same year HFPL was admitted as a
partner in Chandramohan company.

1986-April HFPL takes over Chandramohan company. HFPL was

allowed to register the brand name 'Arun' in its own name subject to a
royalty payment of 1% on the gross icecream sales.

1991-Icecream Factory (Atlantic) - Salem Inauguration.

1993-Hatsun Dairy Private Limited (HDPL), promoted by M/s. Hatsun Foods Private
Limited, established. The Salem Dairy - Inauguration.

1996-M/s. Hatsun Milk Food Limited (formerly known as Hatsun Foods Private
Limited) goes public.

1998-Changes name to M/s. Hatsun Agro Product Limited. Amalgamation of M/s.

Hatsun Milk Products Limited with M/s. Hatsun Agro Product Limited.

2000-Kanchipuram Dairy Acquisition.

2001-Amalgamation of M/s. Ajith Dairy Industries Limited with M/s. Hatsun Agro
Product Limited.

2003-Amalgamation of M/s. Hatsun Foods Company Limited with M/s. Hatsun

Agro Product Limited.
2004-Dairy Ingredient Plant - Inauguration (Salem & Kanchipuram)

2007-Dairy Ingredient Plant – 2nd Drier in Kanchipuram

2009-Dairy Ingredient Plant - Inauguration (Palacode)

2013-Vellichandai - Milk & Milk products manufacturing & processing unit - March
2013

Karur - Feed Manufacturing Division - Oct 2013

Chitoor – Milk & Milk products manufacturing & processing unit - Dec 2013

Hyderabad Plant – Milk & Milk products manufacturing & processing unit- Dec
2013
2014-Tirunelveli – Milk & Milk products
manufacturing & processing unit - June
2014

Guduvanchery – Ready to eat Food

Manufacturing Plant - Nov 2014.

2016-Palani – Feed Manufacturing Division

- Feb 2016

2020-Hatsun Agro Product Ltd: A 50-year

young company's many "firsts"!

Hatsun Agro Product Ltd reaches retail

milestone with 3000 outlets
Quality Process

•Food Safety Management System Standard of ISO 22000:2018

•Food Safety System Certification 22000

•Export Inspection Council of India (Ministry of Commerce & Industry Govt. Of

India) Certificate of Approval of Quality for Export of Milk Product.

•Food Safety and Standards Authority of India license for all manufacturing
and processing facilities.
•KANCHIPURAM-Dairy & Powder Plant
•SALEM-Ice Cream & Powder Plant
•MADURAI-Dairy
•THALAIVASAL-Dairy
•TIRUNELVELI-Dairy
•REDHILLS-Ice cream
•VELICHANDAI-Milk product division
•SALEM MPD-Milk product division
•HONNALI
•Dairy
•BELGAUM
•Dairy
•HYDERABAD
•Dairy
•CHITTOOR
•Dairy
•CHENNAI
•Head Office
•CHILLING CENTRES
•Uthangarai, Gudimangalam, Vandavasi, Polur, Palani,
Watrap,Edappady and Sathyamangalam.
 FSSC 22000

PALOCODE
Dairy & MPD & Powder Plant

HALAL

REDHILLS
Ice Cream

SALEM
Ice Cream & Powder Plant
1. Salem - MPD
2. Kancheepuram- Hatsun cow milk, Lite curd, Ar.Milk
3. Tirunelveli - Arokya milk, curd
4. Chennai - Red hills - Ibaco
5. Palacode -kolasanahalli - DI plant
6. Madurai - Arokya milk

7. Thalaivasal - Arokya milk, curd, ziplock curd,

Hatsun curd
8. Vellisandhai - curd, ESL milk (FCM&SM)
9. Salem - Arun Ice cream
10. Karur - Oyalo (Project started)
11. Walajapet - Polyfilm production
12.Uthiyur
13. Chittoor
14. Hyderabad - Double Toned milk
15. Sangareddy
16. Belgaum
17. Honnali - Arokya milk
18. Sangola
19. Mangalwedhe
 34
7.15
Lakh litres of
Lakh Farmers
milk procured
Enrolled
every day

10000+ 20
4800+
Hatsun Milk Processing
Vehicles
Banks Plants

Associated with
10905+ 20278+
202599+
Employees Coolers
Retailers

Our brands
52993+ operate in
Freezers 42
Countries
 HAP VISION
To be the Nationally Admired OSHE leader in
the Agro industry space (OSHE-Occupational Safety
Health and Environment)

HAP-MISSION
Develop and Implement a world class OSHE
framework by leveraging leadership commitment
and stakeholder engagement and create a safe
and productive non polluting workplace.
• Arokya Milk
• Arun Ice creams
• Hatsun
• Hatsun Daily
• Ibaco
• Santosa
• Oyalo
• Aniva
 Arun Icecreams is probably the most well known

Hatsun brand. When other ice cream brands opened

parlours exclusively in the city, Arun decided to take

to suburban and even rural areas, leading the ice

cream into the hearts of millions. Arun caters to

different people with different tastes with a whole

range of ice cream bars exclusively for kids and

novel ice cream flavours like indian sweets. The

brand also consistently introduces new flavours every

season, just to make sure customers have something

fresh to look forward to every time they walk in to an

Arun Icecreams parlour.

 Neapolitan bar

Two in one mango

Watermelon
Spiral-wildberry,venilla&pineapple

Fun wheel-vanilla&chocolate

Trio-raspberry,vanilla&mango
 Kulfi king

Jolly train

Kulfi pista bar

Belgian Chocolate Kesar Pista Red Velvet
Butterscotch Blackcurrant Double Chocolate
 Vanilla

Butterscotch Mango
 Coffee With Choco Chips

Lychee

Gajar Ka Halwa
OVERVIEW

Launched in 1995, Arokya is the flagship brand

of Hatsun Agro Product Limited. We have won
the trust of millions of consumers across Tamil
Nadu, Andhra Pradesh, Telengana, Karnataka
and parts of Maharashtra.The popularity of
Arokya can be attributed to the fact that a
whole eco-system has been built around the
brand promise “Goodness with care, from our
villages”. Great care and hygiene goes into the
procurement, processing and packaging of
Arokya Milk to ensure it’s made available to
you in a healthy way.
 The Arokya brand of milk is brought to you from the nearest village around you -

sourced only from healthy, well-nourished cows, reared by trained farmers. An ideal
mix of nutritive feed is served to the cows, which includes specially grown green
fodder, nutritional cattle feed and clean, abundant water. Over 3 lakh farmers
provide milk to around 9,000 of our milk banks, covering over 12,000 villages.
 Milk FROM THE NEAREST VILLAGE
Arokya is synonymous with goodness and care. We procure our milk from the nearest villages and
straight from the source – well-nourished cows nurtured under trained dairy farmers. Our network
of about 9000 milk banks, spread over 10,000 villages across Tamil Nadu, Andhra Pradesh,
Telangana and Karnataka make sure the goodness from the villages is delivered right to your
doorstep.

Tamilnadu, Andhra Pradesh, Karnataka, maharastra, telungana.

Full cream milk

Standardized milk
Toned milk
Double toned milk
Fat - 6%
Snf - 9%
As the name suggests, it’s
just right for every member
of the family. With 4.5% fat
content, it’s a rich, highly
trusted nutritional source for
both kids ‘n adults. It’s
pasteurized and
homogenized to retain
nature’s goodness and
natural taste at the same
time.
Fat - 3%
Snf -8.5%
Fat - 1.5%
Snf - 9%
After becoming a household brand in the Milk category, Arokya Curd has been
launched. The curd in an extension of our product offerings keeping the “Goodness
with care, from our villages” intact. The curd is thick, creamy and so tasty that it
gives a home-made feel.
It’s available in three formats : Zip lock pouch, Cup and single use pouch.
Made Naturally with Lemon.
Fresh, soft and succulent
paneer, perfect for a wide
range of recipes.
 VISION
To be the most favorite neighbourhood dairy shop in India.

MISSION
To provide daily customer needs with fresh dairy products in friendly buying

experience by courteous, self-motivated and smiling team in a clean environment .

 CORE VALUES

Customer Focus Reliable

passion Delivering Excellence

 Hatsun Agro Product Ltd. has introduced HAP daily, a series of outlets that stock

dairy products of the highest quality. Which means that customers can now shop for
their favorite Hatsun products from under one roof.

 HAP daily houses brands such as Arokya, Hatsun and Arun Ice creams.

 When customers walk into a HAP daily parlour, they can look forward to shopping

for these products in an easy, hassle- free manner

ARUN ICECREAMS AROKYA HATSUN HAP

ibaco lets you craft your own sundaes from a
choice of exotic flavours, toppings and sauces.
This unique brand from Hatsun Agro Product Ltd.
offers 36 flavours inspired from exotic places
around the world, and aims to offer more
choices and deliver greater standards of taste
to its customers. You can also pick from a whole
range of ice cream cakes and create your own
ice cream bars and cones.
 cold brews ice cream shakes

ice cream ice cream cakes

OUR PRODUCTS
 Skimmed milk products

 Butter oil

 Dairy whitener

 Salted butter

 Unsalted butter

 Ghee

 Fresh frozen cream

 Full cream milk powder

Aniva
Making Occupational Safety and Health a precedence in everything
we do.
Ensuring compliance with all statutory regulations pertaining to
Safety, Health & Environment in letter and spirit.
Involving employees and empowering them to achieve continual
improvement in Occupational Safety, Health & Environment
performance.
Establishing suitable procedures and work practices, providing the
necessary resources and conducting regular training.
Reporting, investigating and taking corrective action on all incidents
or situations that have a bearing on Occupational Safety , Health &
Environment
From 2008 onwards, milk processing was started (13 years) and then curd
manufacturing was started in Thalaivasal, HAP milk processing plant. The 8th plant
was commissioned at Thalaivasal. There are 20 storage silos, where it has total
capacity of 3,60,000 litres processed milk. Standardized milk, full cream milk and
toned milk are processed and packed in Thalaivasal plant. In curd- Arokya curd,
Hatsun curd pouch and Zip lock Arokya curd pouch are processed. 5,10,000 litres
of raw chilled milk can be stored in this plant.
PMST-3,60,000L
RMST-5,10,000L

CAPACITY:

Active Bulk Cooler (ABC) = 1000L, 1500L, 3000L Chilling

Centres (CC) = upto 100000
 30kl capacity of tanker is rarely used.
Total number of route = 32
Number of route in morning =16
Number of route in evening =10
Number of chilling centres = 26
Number of active bulk cooler = 199

Capacity(ltr) No of tankers No of compartment No of drivers

9000L 19 3×[3100] 2

15000L 5 2× [7500] 2

20000L 2 2× [10000] 1
 Gate entry

Weighment

Reception area

Automatic plunger and taking sample (lab)

Unloading

Filter

Chiller (30kl)

RMST
 Organoleptic tests:
This test permits rapid segregation of poor quality milk at the milk receiving
platform. No equipment is required, but the milk grades must have good
sense of sight, smell and taste.

QCR number

Tanker no

Arrival time

Route

Temperature

Unloading time

Silo number

Tanker quantity [9kl/15kl/20kl]

Empty weight

Soap oil wash for gasket

Soap oil brush wash inside tank

Hot water (75°c-80°c) by using spray ball

Chill water (<10°c)

After cleaning load 50L/compartment of chill water (5.5°c)

Chilling centre
 Tanker washing report (slip) – seal no, start time, finished time.
According to SOP, tanker washing time – 45 mins.
Line brush is used for inline pipe cleaning. Fat, SNF,temp

4 Seal (green color) – 3 seal for gasket [top] and 1 seal for valve

TANKER LOADING FOR CONDENSED SKIM MILK

Tanker washing procedure + caustic (alkalyic)
Condensed skim milk silo

20kl chiller (<2.5°c)

Tanker

To other processing plants of HAP

 Farmer
RAW MILK CHILLING OPRP -01
Hatsun Milk Bank (HMB)
(B) CHILLING TEMPERATURE
Can RMRD (35°C & 37°C)
≤4.0°C
Can lid opener –plunger

Conveyor (OT test)

Weighing bowl

Taking sample (lab)

Dump tank Pump

Chiller (30kl) [<10°]

Final chiller

RMST-silo
Total number of routes = 41
Total number of centres per route = 15 Number of cans per route:
Minimum = 37 or 38 cans
Maximum = 42 or 44 cans
Total litres of milk procured/day = 1,00,000L (apprx)
Morning=60,000L
Evening =45,000L
Approximately 2500 cans procured per day.
Milk is procured from Hatsun Milk Bank which is situated within 50kmaround
thalaivasal plant
Aluminium cans are numbered and its capacity is 40 litres.
 Quality assurance be defined as part of quality management focused
on providing confidence that quality requirement will be fulfilled. The
confidence provided by quality assurance is twofold- internally to
management and externally to customers, government agencies,
regulators, certifiers and third parties.

SCADA: (Supervisory Control and Data Acquisition)

SCADA is a computer-based system for gathering and analyzing realtime

data to monitor and control equipment that deals with critical and
timesensitive materials or events. Production section will verify SCADA
batchwise and release it to Quality.
Sample is taken from each compartment of a tanker by a well trained
employee wearing safety belt. Sterilized bottle is used. Temperature of
milk should be ≤5°C. Tanker number and valve seal number are verified.

Sampling for silo milk

The person who is taking sample must be sanitized or should wear
gloves. Sample cork should be cleaned by using 70% Isoprophyl alcohol,
Iodophore and linebrush. Temperature of the milk should be checked.
MBRT (Methylene Blue Reduction Test):

Take 10ml milk in a test tube.

Add 1ml of methylene blue solution into the test tube and stopper.
Place the tubes in hot water bath with a temperature of 37±1°C.
Record this time and check the colour of milk at regular intervals.
Observe the decolouring.

MBRT METHYLENE BLUE REDUCTON TEST

VARIANT GOOD AVERAGE OK POOR

Raw >1.30 1.15-1.30 1-1.5 <1.00
chilled
milk
Market 7.00 6.30-7.00 6-6.30 <6.00
milk
Take 20ml of milk in a 100ml beaker.
Add 8 drops of 1% phenolphthalein indicator.
Titrate against 0.1N NaOH till faint pinkish colour appears.
Titrable acidity % = Burette reading (BR) × 0.9 Volume of sampling taken
The titrable acidity percentage of milk ranges from 0.128-0.148.

Alcohol Test:
Take 5ml of milk in a petriplate/test tube. Add
5ml of ethyl alcohol (68%, 70%, 72%, 75%, &
78%)
Formation of precipitate indicates that alcohol
test is positive (+ve).
The concentration of alcohol up to which, there is
no formation of precipitate is noted.
MILK
TEST MEDIA INCUBATION COUNT
TIME& TEMP
Coliform Violet red bile 30±1°C for24±2 Absent
agar hrs
Enterobacteria Glucose agar 37±1°C for 24±2 Absent
hrs
Thermophiles Plate count agar 55±1°C for 48 hrs Less than 500
Total plate count Plate count agar 30±1 °C for 72 Min 1000, max
hrs 7000
Proteolytic Plate count agar 30±1 °C for 72 Less than 300
hrs
CURD

TEST AGAR INCUBATION COUNT

TIME& TEMP
Coliform Violet red bile 30±1°C Absent
agar for24±2 hrs
Enterobacteria Glucose agar 37±1°C Absent
for24±2 hrs
Yeast & mould YEDCA 25±1°C for 5 Absent
days
Raw chilled milk (≤5°C)

Silo

Float control balance tank

Regeneration-1 (55°C to 60°C)

Regeneration-2 (70°C to 75°C

Homogenization (stage2-500psi+stage1-
1500psi

Heating (82±2°C-CCP
Regeneration-1 (55°C to 60°C)
Holding coil (15 sec) Chilling (≤4°C)
Flow diversion valve (FDV)
PMS(≤5°C)
Regeneration-2 (70°C to 75°C )
 Raw chilled milk from silo (≤5°C)

Balance tank

Pump

Regeneration-1 (55°C)
Skim milk
Cream
Regeneration-2 (60°C)
Regeneration-1 (55˚C)
PHE chiller (< 10˚ C)
Heating(74±2C°)
Chilling ( ≤5˚C)
Jacketed vat silo
Holding coil (15sec)
PHE chiller(2˚C)
Flow diversion valve (FDV)
silo
Regeneration-2 (60°C)

Cream separator (7000rpm)

Skim milk from silo
Retentate = condensed skim milk
Permeate = water
Balance tank (200L)
Capacity - 5kl/hr
Pump(15Hp)
Production - 2225L/hr (condensed milk)
Permeate - 2775L/hr (water)
Line filter
Membrane – changed 2years once,
polyethylene sulfonate (polyethersulfone)
Boost pump(7.5Hp)

Pump (20Hp) Loop A Permeate

Pump(15Hp) Loop B Permeate

Tubular heat exchanger

Reuse
concentration valve (permits if TS=20)

Chiller

Silo (2-3˚C) (retentate)

Daily: full CIP
Flush (30˚C for 10 mins)
Alkalic (48˚C for 30 mins)
Alkalic + soap oil (48˚C for 45 mins)
Acid (48˚C for 30 mins)
Flush (30˚C for 10 mins)
Alkalic (48˚C for 30 mins)

Weekly: full CIP +sanitizer

Flush (30˚C for 10 mins)
Alkalic (48˚C for 30 mins)
Alkali + soap oil (48˚C for 45 mins)
Acid (48˚C for 30 mins)
Flush (30˚C for 10 mins)
Alkali (48˚C for 30 mins)
Sanitizer (25˚C for 10 mins)
Capacity : 5 KL
OPRP RCM :storage≤5˚C
OPRP : Processed milk
storage ≤5˚C
CCP : 92±2˚C for 10mins
Type : Downstream
process
 There are 14 packing machines in milk processing section with total of 25 heads
which has state-of-the-art packing technology. They are 6L, 5L & 10K capacities

Process milk silo (<5°C)

Flow plate chiller(10kl) (<5°C)

Insulated packing pipeline

Float control buffer tank

Inlet

Filling

Packing

Coldroom
Sku( in ml) MRP Pouch/crate L/Crate STD. Weight

150 10/- 60 9 157-160

200 13/- 50 10 207-210

250 16/- 44 11 259-262

500 31/- 24 12 517-520

&30/-
1000 62/- 12 12 1033-1063
&60/-
2000 124/- 6 12 2070-2073
&120/-

5500 330/- 2 11 5690-5695

&341/-
 Sku( in ml) MRP Pouch/crate L/Crate STD. Weight

100 6/- 90 9 104-107

170 10/- 60 10.2 177-180
250 14/- 44 11 259-262
500 28/- 24 12 517-520
1000 54/- 12 12 1034-1037
5500 297/- 2 11 5690-5695

TONED MILK
Sku( in ml) MRP Pouch/crate L/Crate STD. Weight

250 12.50/- 44 11 259-262

500 25/- 24 12 517-520
1000 50/- 12 12 1033-1035
Test for packaging material (poly film roll)
Width
Length
Thickness
Tape test
Tart & impact test
Density

There are 6 curd packing machines which are double headed with only one
single head. For curd, one atomic machine is there which has max speed of 100
other are 40 &80. Atomic type of machine uses alarm while low level of milk,
starts after attaining heating temperature& can control flow of milk by valve.
This machine has heater works without water.
Batch coding : T43F5 + time here, T=Thalaivasal 43=Batch no F=Operator
5=Head no
 Pick, fill & seal machine are customized to handle zip lock pouch. It is a unique &
flexible self-standing package.
Pick (by vaccum)

Open (by vaccum) (no pouch-no fill-no seal

option by default) Air filter (6kg/cm2 )

Curd filling

Expanding 35

Seal (heat =125.2˚C)

Pressing

Conveyor

Batch code

Crate
HATSUN CURD
SKU (IN g) MRP PACK/CRATE L/CRATE
140 10/- 60 8.4
200 14/- 50 10
500 33/- 24 12
5000 310/- 2 10

AROKYA CURD

75 5/- 120 9
140 10/- 60 8.4
200 14/- 50 10

ZIP LOCK CURD

400 35/- 12 4.8

It is a large refrigerated room designed for storage of goods in an environment
below the outdoor temperature. Puf insulated cold room panels are used to prevent
entry of heat. In thalaivasal plant, there are 4 cold room with 2,00,000L capacity.
Total no.of condensers are 22. Ammonia is used as refrigerant.12 crates are
arranged vertically 5 loading point (night) & 4 loading point (days).
Total number of crates = 22,225
 A typical crate washer consists of a washing section & a rinsing section. The nozzles
that are mounted on the spraying racks will produce the mechanical action of the
temperature controlled & ZLD and RO permeate water is used.
A conveyor is used to transport the crates through the machine with a certain speed
without causing pollution. They are environment friendly as it saves water, reduces noise
pollution, air pollution as there is no generation of gas, smoke & heat.
Frequency:
24 hours once alkali CIP.
10 days once acidic CIP

HALF CIP (1 HOUR)

CLEANING METHOD STRENGTH & CIRCULATION TIME

TEMP/PARAMETOR
Flush Normal water 5mins

Alkal 0.4 to 0.5 (14pH)(70- 20mins

78°C)
Flush Recovery 5mins

Hot water Above 80°C 20mins

Flush Prerinse water 5mins

FULL CIP (2 HOURS 30MINS)
Flush Normal water 5 mins

Alkalic 0.4 to 0.5 (14pH)(70- 20 mins

78°C)
Flush Recovery 5 mins

Acidic (0.8 to1)(1pH) (60°C- 20 mins

68°C)
Flush Recovery 5 mins

Alkalic 0.4 to 0.5 (14pH)(70- 20 mins

78°C)
Flush Recovery 5 mins

Hot water Above 80°C 20mins

Flush Recovery 5 mins

 Dispatch of market milk, curd is done at thalaivasal plant. Dispatch is done based
on the order placed by Hatsun Distribution Centre (HDC).Order placed by HDC‟s, is
accepted by the dispatch department. Then, the order is sent to the production office,
where in the available stock is analyzed and production is planned accordingly. Then
billing of the order is done and the milk is transported via refrigerated container
trucks in crates and unloaded at a common point (Transit point), from where various
HDC‟s collect their orders. Each route has one or more Hatsun Distribution Centres

Approximate sales value per day is 3,00,00 includes milk & milk products.
There are 41 vehicles for 39 routes transport facility upto transit point.
TYPE OF VEHICLES CAPACITY TOTAL CRATES

1109 6000L 527

Lorry 9000L 725

10 wheel tarurus 14000L 1724

Transit point vehicles

HDLL (puff container with AC) – long life products
HDC (puff container) – short life products
Vehicles are tracked using vehicle tracking system (GPS) & temperature are
noted regularly.
PRODUCTS – SM,FCM,TM, hatsun cup box, arokya cup box, arokya pouch
curd, arokya zip lock curd, sweetcurd, hatsun pouch, hatsun lite curd, lassi,
butter milk, paneer, ESL can milk (SM&FCM)
 Material storage Production

Supplise Distribution

MATERIALS FLOW
Suppliers Customers
Cash
INFORMATION FLOW
Supply planning Sales forecasting

Production scheduling Production planning

INFORMATION TECHNOLOGY
Packing material:
Primary – direct contact with product
Secondary - indirect contact with product
From walaja, vellore (hatsun polyflim processing plant)

Warehouse
Polyflim (milk, curd) – A,B,C,D
Electrical material – E
Civil material - F
Plant engineering spares – G,H
Plant consumables – I,J
CC consumable – K,L
CC engineering spares – M,N
ABC engineering spares – O,P
 Purchasing ensure timely delivery of material from vendors, generates & tracks
purchase orders & works alongside the receiving department & the accounts payable
department to ensure that promised delivers were received in full & are being paid
for on time.
Purchase order

Vendor

Gate entry

Goods receipt

Store

Accounts

Invoice receipt

Within 7 days payment

Emergency siren location in,

Microbiology Lab
Dispatch
Packing hall
ABC Fire Extinguisher

Suitable for use with fires involving ordinary combustibles, flammable

liquids & energized electrical equipment.
Fire Hydrant System (at 8 locations)

To give best possible source of

water to each corner of the building.
Hose reel at boiler section

Sprinkler system
Ammonia usage area
Ware house

SCBA (self – contained breathing apparatus)

In ammonia usage area.

WORK PERMIT SYSTEM

Hot water
Height work
Confined space entry
Chemical handling work
Electrical isolation permit

First Aid Box At,

Main gate
Hygiene block
RMRD
AED – Automated External Defribrillator(at gate)
To help those experiencing sudden cardiac arrest
Lockout tagout –
To ensure that equipment is shut down & inoperable until maintenance or repair
work is completed.
O2 Dectector –
Should maintain minimum – 19.5
Maximum – 25
Modular fire extinguisher – (ABC type)
Filled with MAP dry powder
MAP – mono ammonium phosphate
Silo handrails
Chemical handling PPE(personal protective equipment)
Rainfall monitor gauge
Emergency preparedness kit –

Foldable structure
Eye wash with body wash shower
ERT cap (emergency rescue team) Aluminium scaffolding – to support a work
while maintenance
Portable eye washer at LAB & CIP
PPE‟s box
Auto glow taper
Emergency exit location in LAB & RMRD
Today India is a leading producer of milk products. Milk is one of the foods
which sum to have no substitute. It is also an excellent growth medium for
microbes & hence to be processed before consumption. HAP has its unique
quality & wide range of products in a well packed manner.

The conclusion of this project was to study the processing operations of milk &
curd, SOPs, CCPs, WTP, ETP, Refrigeration, Boiler unit, testing of milk samples
by various instruments in the QA, QC, microbiology, food & human safety &
waste management of Hatsun Agro Products Ltd, Thalaivasal