P.G.

Department of Biotechnology
Khalsa College
Amritsar

INDUSTRIAL VISIT (BTP-277)

Report
Verka Milk Plant
Amritsar
In-charge and Organizer: Dr. Jaspreet Singh

SUBMITTED TO: SUBMITTED BY:

Dr. JASPREET SINGH Keerty Rani
Dr. HARMANPREET KAUR B.Sc. BIOTECHNOLOGY
SEMESTER- 4
ROLL NO. 22701027
 Acknowledgment

Industrial Training allows us to enhance our knowledge and skills. We tend to gain
an awareness of the industrial background and their work.
With a sense of gratitude and heartiest honor, I would like to thank Dr. Kamaljit
Kaur, Head of Department of Biotechnology, Khalsa College Amritsar. I would also
like to thank my professors, Dr. Harmanpreet Kaur and Dr. Jaspreet Singh, for
allowing us to visit the Verka Milk Plant in Amritsar and get an Industrial Experience
of how Verka Milk Plant produces various dairy products. The site visit has widened
my vision to understand the production of various dairy products at its manufacturing
unit of Verka Amritsar.
 Introduction

Verka Milk Plant, Amritsar was the first Milk Plant established in the Northern region.
The foundation stone of the plant was laid by the then Hon’ble Chief Minister of Punjab,
S. Partap Singh Kairon on 20th August 1959. The equipment of the plant was gifted by
the United States of America, thus assisting and providing the Indian People with a more
nutritious diet containing nature’s most perfect food.

In the beginning, the processing capacity of the plant was 60,000 LPD, with 5.0 MT per
day drying capacity & 10,000 liters of Liquid Milk Supply under the control of the
Punjab Government. This was the first Composite Milk Plant in Northern India and was
established at the Verka Village on the outskirts of Amritsar city. Therefore, the brand
name of all the products was named as ‘VERKA’ which is the internationally famous
brand name for Milk Products. The product range includes Pouch Milk, Ghee, Milk
Powder, Dahi, Sweetened Flavoured Milk (PIO), Paneer, Milk cake, Panjiri, Plain sweet
& spiced Lassi and Kheer, etc.

The milk shed area of this union has been covered with six established milk chilling
centers namely MCC Mehta, Patti, Lopoke, Bhathal Sehja Singh, Khadoor Sahib,
Fatehgarh Churian & two in the hired locations namely Ajnala and Tahli Sahib.
Nowadays, 628 MPCS and 261 commercial dairy Farmers are pouring milk into this
plant. Milk Union is providing Artificial Insemination facilities to 376 milk producers’
cooperative societies through 78 cluster centers and 64 Single A.I center.

Further, under the rehabilitation plan which was started in April 2009, the upgradation of
milk processing was done and new machinery was added including a fully automatic
refrigeration unit, semi-automatic CIP unit, Milk pasteurizer, Milk Silos, SFM filling
machine, cold store, etc. to facilitate efficient processing, packing & safe storage of milk
& milk products. To meet the demand of consumers and increase processing capacity to
handle more milk available in the milk shed area. A new liquid milk processing plant has
been established having a capacity of 2.5 LLPD expandable up to 5.0 LLPD. This is a
fully automatic unit having state of art and energy-efficient technology for milk
processing and an auto-standardized unit has also been installed.

The plant has also adopted Quality Management System requirements as per the
international standard ISO-9001:2015 and Food Safety Management System as per IS
15000:2013 on Hazard Analysis and Critical Control Points (HACCP) to ensure the
highest quality products with build food safety for the consumers.
Objectives of the Milk Plant are: -

 To uplift the social and economic status of milk producers.

 To develop dairy as an industry allied to agriculture.
 To provide veterinary aids to animals of milk producers at their doorstep.
 To provide better-quality cattle feed at reasonable rates.
 To educate the milk producers about lowering the cost of milk without
compromising quality.
 To create employment opportunities for rural youth through milk production
activities.
 To provide awareness among milk producers for socio-economic change through
cooperative setup.

Present Status of Verka Milk Plant

 Present status number of societies increased from 94 to 802 and its membership from 5400 to 78500
 Milk procurement has increased from 10200 LPD to 250000 LPD
 The highest milk price is being paid to the milk producers as compared to other plants in the states.
Products being manufactured by AMRITSAR PLANT are sold at premium rates throughout the country
and in the international market.
 City supply has increased from 66000 LPD to 198000 LPD.
 Turnover of the plant has touched to 283crores . Profit of the union has increased manifold . capacity
utilization of the plant is morethan 85%.
 Location of sites:
 Amritsar
 Bathinda
 Chandigarh
 Faridkot
 Firozpur
 Gurdaspur
 Hoshiarpur
 Jalandhar
 Ludhiana
 Patiala
 Ropar (Mohali)Sangrur

Sr. No. MILK HANDLING AND PRODUCT CAPACITIES – MILK UNION AMRITSAR

1 City Supply 120000 Litres per day

2 Dahi 20 MT/day

3 Lassi 50000 Litres per day

4 Paneer 1000 KGs per day

5 Kheer 700 KGs per day

6 Ghee 5 MT/day

7 Powder Plant 10 MT/day

8 Sweetened Flavoured Milk 40000 Bottles/day

9 Panjiri (CDPO) 5 MT/day

10 Table Butter Nil

  MILKFED has its milk unions in almost all the districts of Punjab. These district
units are: - These plants in all these unions are being run under the brand name
VERKA

PRODUCT Manufactured
 PASTEURIZED MILK
 Standard Milk
 Double Toned milk skimmed Milk
 Flavored Milk (PIO)
 CURD
 PANEER
 BUTTER
 GHEE
 MILK POWDER
 Skimmed Milk Powder
 Whole Milk Powder

ORGANISATION NETWORK
For the smooth running of the plant, various sections are managed by the management.
Every activity is delegated to a particular section. Top management can't decide on every
problem, so various risks are delegated to various sections. These sections are interrelated
to have frequent contact with one another and it is easy to share the information. These
integrated tasks teams handle their problems and make their supervision easy.

The following are the sections in the Verka Organization.

1. Procurement Section
2. Production Section
3. Quality Control Section
4. Marketing Section
5. Accounts Section
6. Administrative Section
7. Engineering Section
8. Purchase Section
9. Store Section
10. Security Section
This Photo by Unknown Author is licensed under CC BY-SA-NC
 Product Flow Chart

MILK

Fluid Milk Surplus Fat Skim Milk

Packing Given Table White Skim Milk

Preference Butter Butter Powder

Lassi Ghee

Milk-Cake

Dahi

Kheer
 POWDER SECTION
 These are definite indications of greater future productions of dried milk & milk
products due to their better-keeping quality, they require less storage space &
lower transportation costs. All these are economically attractive.
 Dried milk provides a means of handling the excess milk supply in a dairy factory
during the flush season, while in a lean season that is meant for the production of
dry milk can be derived to market milk. Thus, dried milk is called the balance
wheel of the dairy industry.

POWDER PLANT FLOW CHART

Condensed Milk Air

Air Heated by Steam Filter

Food Pump

Entry inside the drying Chamber through the atomizer

Milk Powder and air bottom of drier

Air Cyclone Separation Powder

PROCESS CONTROL of Powder
 Lumpiness in Powder
 Ensure proper colling of powder
 The dehumidifier should be properly operating with low moisture in the Final
Product.
 Increase Flow Rate
 Adjust outlet temp Burnt Powder Particles
 Adjust inlet temp
 Check the function of feed flow controller & Feed pump
 Nozzle of jets are whether chocked partially sooty powder
 Clean up the air heater with very fine powder particles
 Increase in degree of concentration
 Control the feed temp. Solubility Index Increased
 Check the outlet Temp
 Control Feed

Rate

Additional sections:

 Dahi Section

 Butter Section

 Lassi Section

 Kheer Section

 CREAM Section

CREAM SEPARATOR
That’s why creaming phenomena occur but natural creaming is very slow due to
the smaller diameter of fat globules. Hence somehow if we increase the separate
the force acting on the fat globules to rise it up we can separate cream much
efficiently and quickly. In dairy plant cream separate are used where centrifugal
force is given to milk articles causing faster separation of cream (fat) from serum
portion . Generally impossible to work .

Separation is done either of

 Cold milk : cause high velocity of milk and less efficiency of separation
 Hot milk : cause low velocity of cream and high efficiency of separation
Technically 40c and above is the temperature of separation but
microbiologically temperature should be 25c or less as mesophilic organism
grows faster at 40c which will cause poor shelf the life and souring of cream

MILK ANALYZER

This machine measures 7 parameters they are;

 Fat
 Snf
 Lactose
 Protein
  Total solubility
 Acidity
 Urea (adulterant )

1. LIQUID MILK PASTEURISED POUCH PACKED MILK

It is pouch packed milk. It shall be kept under refrigerated conditions. It is packed
in half litre and one litre pouch. Its length of shelf life is 48 hours under
refrigerated conditions. Verka Milk plant is preparing 3 types of Milk pouch.

FULL CREAM MILK FAT FREE MILK STANDARD MILK

2. DAHI/CURD

Dahi or curd is the product obtained from boiled milk by souring, natural or
otherwise, by harmless lactic acid or other bacterial culture. It should have the
same percentage of fat and solids-not as fat as the milk for which it is prepared.
3. VERKA LASSI

Also called chaas refers to Desi Butter Milk which is by product obtained when
chumming curd led whole milk with curd indigenous devices for the production
of desi butter. Verka lassi is very popular especially in Punjab and it is also liked
by people of other state. It comes in the 200ml Tetra Pack. It comes in three
flavours i.e. salty, sweet and normal.

4. BUTTER

Butter may be defined as a fat concentrate which is obtaining by churning

cream, gathering the fat into a compact mass and then working it. The product
obtained from cow and buffalo milk or a combination thereof, with or without
the addition of commom salt and colouring matter. It is kept under refrigeration
four 3 months. This comes in packs of 10gms,100gms,500gms.
5.PANEER/CHEESE
Paneer refers to the small sized soft cheese.It is preserved under refrigrated
conditions for 20 days from the date of packing. The product is packed in
polyfilm bags. The product is size is 200gms.

6. ICE CREAM
Ice cream may be defined as a frozen dairy product made suitable blending and
processing of cream and other milk products, together with sugar and flavour,
with or witouht colour with the incopration of air during the freezing process.
They are mainly 3 types of verka Kulfies e.g. Malai Kulfi, Choco bar and
Mango bar. Malai Kulfi is made with milk and malai.
PASTEURIZATION OF MILK
 The term pasteurization has been called after the name of scientist ‘louis
pasteur’. The term pasteurization , as applied to market o milk today refers
to the process of heating every particle of milk to at atleast 63c for 30
minutes or 75+-2c for 15 minutes. The milk should be immediately cooled to
5c or below. Pasteurization is divided into 3 categories:-LTLT (Low
Temp)for Long Time) 63c for 30 min. HTST(High Temp. For Short
Time)72c for 15 sec.

RAW MILK RECEPTION

 The quality of dairy products is very dependent on the quality of milk used
to make them. Due to this remark, raw milk reception at the DOCK is the
first important place of any dairy plant.
 1.unloading
 2.grading
 3.sampling
 4.weighning
 5.testing
DESIRABILITY OF THE PRODUCTS
 Fat not more than 3.10%
 TS not more than 13.10%
 Acidity 0.80% to 0.90%
 Taste and flavour -normal
 Shelf life-(1) Traditional curd -6 days; (2) premium curd -10 days
 Packing 100g, 200g, 400g in cups, and 500g in pouches.
Group photo in Verka Milk Plant, Amritsar
CONCLUSION

Verka milk plant is operating an milk products in amritsar. The verka milk plant
was 1.00 lac liters per day but now the capacity is about 4 lac liters per day by
the quality of production of verka milk plant ans company growth is increased
day by day.
Bibliography:
 https://www.scribd.com/document/484010505/VERKA-MILK-PLANT

 https://www.scribd.com/document/558065421/verka-assignment