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11days@amul
1. ANAND MILK UNION LIMITED
A Project Report on :
“Short term training”
@ Kaira District Co-operative Milk producers’ Union Ltd. , Anand .
► Training Period : Starting From 22/12/08 to 2/01/09
► Shift Time : 12:30pm to 4:30pm
Prepaid By :
► Ronak Thakkar
► Jaymin Zala
3rd Year students of B.E.(FPT) , ADIT , New V.V.Nagar.
2. Anand Pattern
STATE FEDERATION
Marketing
Money
PRODUCTS
DISTRICT UNION
Milk Procurement & Manufauring of Dairy Products
&
Technical Inputs and Co-operative Development
Programmes to Farmers
Money
AI AH FEED EDU
MILK
PRIMARY VILLAGE CO-OPERATIVE SOCIETIES
Milk Production and Pooling through farmer producers
3. Introduction
For a milk farmer, whose life and livelihood is in our
rural hinterland, Amul is, Amul does!
This is the crux of the Amul brand and stems from the
support and ownership by over two million milk
producers of Gujarat
For the Consumer, Amul simply means 'Value For
Money' and Quality as it should be.
Amul makes each bite that much more special because in
our humble way, we care for feelings that are truly
"Indian".
4. HISTORY
In the year 1946 (14th December 1946) the first milk union
was established. This union was started with 250 liters of milk
per day. In the year 1955 AMUL was established. In the year
1946 the union was known as “KAIRA DISTRICT CO-
OPERATIVE MILK PRODUCERS’ UNION”.
The brand name Amul means “AMULYA”.
Amul which inspired 'Operation Flood' and heralded the
'White Revolution' in India.
http://www.amul.com/. Is India's first national cyberstore,
functioning in some 120 cities, and an Amul Cyberstore
Gifting Service capable of serving consumers in more than
220 of our cities, on specific occasions. This has been made
possible by creating an IT network.
5. Amul-2 RMRD
This is very first department of any dairy where truck (cans) loaded
with milk are unloaded and simultaneously the milk is tested and
processed further in other departments. The RMRD at AMUL – 2
received cow milk and buffalo milk in separate cans.
Even today around 60% of mandadis (600) send milk to the amul
dairy by cans each can have capacity of 65lit. Regular 33truks arrive
here in morning. Milk is taken in B.T. & by pump it is forwarded to
the pasteurizer.
7. Milk Pouch Packaging
Here Packaging of milk ,buter milk ,dahi is done. In different
sizes 200ml,500ml & 1lit.(T-special).
* Made by : pre pac , pamar pan , set pac
Pouches are the most popular, convenient and accepted
packaging for marketing of liquid milk. The Packaging Film
Project (PFP) was established to give a competitive edge to the
Co-operative Dairy, by ensuring access to the best quality food
grade packaging pouch film, for high speed pouch filling
machines, that operate at speeds 75 per cent higher than at
present.
* Packaging Film Project, Gandhinagar.
U.V. light is used to protect pouches from bacteria.
speed selector is used for 200,500,1000ml pouches.
Horizontal & vertical sealing injection. – on/off
Impression coder is (of printech India) is used for marking
Mfg. date & Batch no.
Valve control penal : from which we can select inlet tank(silo)
& line. , for different products.
8. Flavor Section
☺Now a days amul is manufacturing of “14” types. 6
– in bottles & 8 –in tins. Namely : KOOL café , coco
, kesar , nutramul , rose , elaichi , Milk sek badam ,
banana , strabery , mango.
☺The plant have capacity to manufacture 1lac. Tins &
1lac. Bottles per day.
☺coming soon is whey milk in coco flavor. (in next 6
months). We are try to make this in R&D
laboratory(central lab) .
10. Amul – 3 Reception & process
“quality is prevention of wrong things”
► Purpose : To ensure that the process of milk reception ,
processing & issue or dispatch as per documented procedure.
12. Name of EQUIPMENT Capacity Number
Raw Milk Silo 1,50,000 Liters 4
Milk Clarifier 30,000 Liters 3 (Rpm – 1400 to 1500)
Raw Milk Buffer tank 15000 Liters 3
Milk Pasteurizer 30,000 Liters / hour 2 (PHE-type)
Cream Separator 30,000 Liters 2
Cream Ripening Silos 40,000 Liters 5
Cream Buffer Tank 40,000 Liters 3
Cream Pasteurizer 10,000 Liters per hour 1 (PHE-type)
Balance Tank 350 Liters 3
Pasteurized milk silo 1,50,000 Liters 2
Butter milk storage tanks 40,000 Liters 2
CIP tanks for tankers Water tank – 8000 Liter Capacity 1 each
Lye tank – 8000 Liters Capacity
CIP tanks Lye tanks Capacity – 10,000 Liters 1 each
Acid tank – 10,000 Liters
Water tank – 8,000 Liters
Sludge Process or Collection Tank 1 Cubic Meter 1
Sludge Stratification Tank 5000 Liters 1
Rinse tank 1
Rail tanker chiller Chilled upto 2ºC 1
Battery S.R.C valve & S.M.P valve
13. Butter
►With the financial help from UNICEF, assistance from the
govt. of New Zealand under the Colombo plan, of Rs. 50
millions for factory to manufacture milk powder and butter
was planned. Dr.Rajendra Prasad, the president of India laid
the foundation on November 15, 1954. Shri Pandit
Jawaharlal Nehru, the prime minister of India declared it
open at Amul dairy on November 20, 1955.
►Largest plant in Asia. ( atli-butli delicious amul)
► They are paying Rs. 87/ton for AGMARK.
►Today , market share 85% Amul , 5% britaniya & 10% others.
► Here 100ton butter is prepared from 2lac lit. cream , everyday.
A
M
U
L
17. Process for rework ghee
(A) process for pouch
• Separate the leakage pouch
• Cut by clipper & take ghee in separate can.
• filter ghee in can,
• Transfer into melting vat
• reprocess by heat
• empty pouch wash two time by hot water & take it into scrap
(B) process for tin
• separate leakage tin & re-work tin
• keep in tray for half an hour
• cut tin & take ghee in separate tank
• Transfer into melting vat & reprocess
• empty tin wash two time by hot water & take it into scrap
18. ☺ Amul ghee is export in 14 countries
• Self life
• 15 months-
AUSTRALIA, U.S.A., KR OMAN,
CP BAHRAIN, QUATAR, HONG KONG,
BRUNEI, CHINA, SINGAPORE, T. KUWAIT.
• 12 months-
ABU DHABI, CP DUBAI, EGT
DHABI, CP DUBAI, EGT DUBAI, JAPAN
19. Laboratory
A. Amul-3 reception lab :
►Following are the test of raw milk ---
1. Determination of titrable acidity in raw milk
2. Clot on boiling test
3. Alcohol Test
4. Methylene blue reduction test (MBR test)
5. Fat Test
6. Determination of phosphate activity
20. B. Central lab
• The dairy factory produces a variety of dairy products like
powder, butter, ghee etc. The various tests are carried out to
check its quality.
• BUTTER
• Following are the tests carried out to check the quality of
butter
1. Determination of moisture content in butter
2. Determination of salt content
3. Determination of SNF (curd) content in butter
• GHEE
• Following are the tests carried out to check the quality of the
ghee.
1. Organoleptic grading test
2. Moisture content
3. Free fatty acid Test
4. Iron test
21. Refrigeration
• In refrigeration there are three diff. sections
1. -2 deg. C. system - Used for chilling the
water
2. – 10 deg. C. system - Used for maintaining
the temperature for ice silo.
3. – 30 deg. C. system - Used for cold storage
and deep freezers
In amul lll 40% electricity consumed by refrigeration plant
Main parts of refrigeration sectios
1) Compressor
2) condenser
3) ammonia receiver
4) economizer
22. Boiler
In AMUL Plant, there are total four boilers and all are fire
– tube type boiler.
The three boilers are having the capacity of 4 to 5 tonnes
steam production per hour and the fourth boiler having the
capacity of 10000 steam productions per hour.
The fuel gas that is used are off two types –
1.Natural gas
2.Furnace oil.
The water used for boiler should fulfill the following
conditions –
The pH is 8.5 to 9.5
Hardness is 10 to 40 ppm
Chloride content is 400 to 800 ppm.
23. Substation
• Contract demand: 2800 KVA
Incoming Main power from two sub station :
1. Anand sub station
2. Mogar sub station
Main two part of dairy plant
1. Amul l & ll
2. Amul lll
For both plants separate sub station ,Anand & Mogar
electricty available for both dairy plants
24. Amul l & ll Amul lll
Main 11 KV power supply comes in pole structure,
↓
Metering point.
↓
4 Nos. High tension (HT) breaker 4 Nos.
↓ 11KV
2 Nos. Transformer 2 Nos.
(1000 KVA) ↓ 440v (1500 KVA)
Low tension LT breaker
↓
Power control centre (PCC)
(MCCB OR Switch Fuse Unit (SFU))
↓
Motor control centre (MCC)
(MCB, Relay, Contactor)
↓
Motor (Machine)
25. ETP (Effluent Treatment Plant)
• 15 lac. Liters wastewater is treated per day.
Sr No. Parameter GPCB range Amul maintained
1 PH 6.5 to 8.5 7.5
2 COD 100 mg/l 80-90
3 BOD 30 mg/l 20-24
4 S.S. 100 mg/l 40-60
5 TDS 2100 mg/l 1100
6 OIL 10 mg/l 3-6
7 CL 650 mg/l 140-165
