Mehr Chand Mahajan DAV College for Women

Sector 36A, Chandigarh

TRAINING REPORT
Submitted to the
Department of Food Science
for the degree of
B.SC. MICROBIAL & FOOD TECHNOLOGY
(2023-2024)

An in-plant training report

Verka Milk Plant, Patiala, Punjab

Submitted by:-
Gagandeep Kaur
B.Sc. I (MFT)
Roll No. 7389
CERTIFICATE
 ACKNOWLEDGEMENT

I would like to express my deepest gratitude to everyone who has contributed

to the successful completion of my internship training at Verka Milk Plant, Patiala.

First and foremost, I am extremely thankful to the Manager/Head, whose

invaluable guidance and support have been pivotal throughout my training period.
Their vast knowledge and experience have significantly enriched my learning
experience.

I extend my sincere thanks to all the staff members and colleagues at Verka
Milk Plant for their cooperation and willingness to share their expertise. Their
assistance and encouragement have been instrumental in helping me understand
the various processes and operations within the plant.

A special thank you goes to my academic supervisor for his continuous

support and insightful feedback, which have greatly contributed to the quality of this
report.

Last but not least, I am grateful to my family and friends for their unwavering
support and encouragement throughout this journey.

Thank you all for your contributions and support.

Date: _________

Gagandeep Kaur
B.Sc. I (MFT)
Roll No. 7389
 INDEX
S.No. Contents Page No.

1. History 1

2. Mission and Vision 3

3. Organization Structure 6

4. Products and Services 9

5. About Milk Production at Verka 11

6. Milk handling product capacities milk Union Patiala 12

7. Milk Pasteurizer 12

8. Homogenization 13

9. Cleaning Parameters 16

10. Dahi 17

11. Composition Maintained By This Dairy Plant 18

12. Flowchart of Dahi Preparation 19

13. Lassi 20

14. Equipments and Utilities Required 21

15. Flowchart of Lassi Preparation 22

16. Paneer 23

17. Flow Diagram of Paneer Manufacturing 25

18. Kheer 26

19. Flow Diagram of Kheer Production 27

20. SFM (Sterilized Flavoured Milk) 28

21. Flow Diagram of SFM Production 30

22. Cheese 31

23. Process Flow Chart of Raw Cheese 32

24. Processed Cheese 33

25. Process Flow Chart of Processed Cheese 34

26. Final Product 35

27. Processed Cheese Spread 35

28. Process Flow Chart of Cheese Spread 37

29. Ghee Section 38

Compositional & Other Standards Of Ghee Maintained By

30. 39
This Dairy

31. Process Flow Chart of Ghee Manufacture 40

32. Treatment of Ghee Residue 41

33. Growth Plant 42

34. Quality Section 43

35. Chemicals Lab 44

36. Testing of incoming Raw milk 45

37. Testing of packaged pasteurized milk 46

38. Challenges Faced by Interns at Verka 52

39. Learning experience for interns at Verka 54

40. Reflection 56

41. Advice for future interns 60

42. Conclusion 61
 HISTORY

Verka is a renowned brand associated with the Punjab State Cooperative Milk

Producers' Federation Limited (MILKFED), which was established in 1973. It was set

up with the aim of improving the dairy industry in Punjab and providing fair prices to

milk producers while ensuring the supply of high-quality dairy products to

consumers.

Here is a brief overview of its history:

1. Formation and Early Years (1973-1980s):

• Established under the Punjab Cooperative Societies Act, Verka aimed

to replicate the success of the Anand model of cooperative dairy

development in Gujarat (Amul).

• Initially focused on organizing dairy farmers into cooperative societies

and setting up milk collection centers.

• Expanded its operations by establishing processing plants and

marketing networks across Punjab.

2. Growth and Expansion (1990s-2000s):

• Verka began diversifying its product range to include a variety of dairy

products such as milk, butter, ghee, curd, paneer, lassi, ice cream, and

flavored milk.

• Invested in modernizing its processing facilities and improving quality

control to meet national and international standards.

1
 • Strengthened its distribution network, extending its reach beyond

Punjab to other parts of India and even to international markets.

3. Modern Era (2010s-Present):

• Continued to innovate with new product introductions and marketing

strategies to stay competitive in the dynamic dairy market.

• Focused on sustainability and ethical practices, emphasizing the

welfare of farmers and the quality of its products.

• Utilized digital platforms and e-commerce to cater to the changing

consumer preferences and shopping habits.

Verka has become a household name in Punjab and is recognized for its

commitment to quality, fair trade practices, and community support.

2
 MISSION AND VISION

The vision of a Verka plant, as part of the Punjab State Cooperative Milk

Producers' Federation Limited (MILKFED), would focus on several key goals to

ensure its efficiency, sustainability, and community impact. Here are the core

elements of a typical Verka plant's vision:

1. High-Quality Production:

• Ensure that all dairy products processed at the plant meet the highest

quality and safety standards.

• Implement advanced technology and best practices to maintain product

consistency and excellence.

2. Sustainability:

• Operate in an environmentally sustainable manner, reducing waste,

conserving energy, and minimizing the carbon footprint.

• Promote the use of renewable energy sources and eco-friendly

practices within the plant operations.

3. Farmer Welfare:

• Support local dairy farmers by providing them with fair prices for their

milk and ensuring timely procurement.

• Offer training and resources to farmers to improve milk quality and

yield.

3
4. Innovation and Efficiency:

• Continuously invest in research and development to innovate and

improve production processes.

• Enhance operational efficiency through automation and advanced

processing techniques.

5. Market Responsiveness:

• Adapt to market demands by producing a diverse range of dairy

products that cater to varying consumer preferences.

• Ensure timely delivery and availability of products to meet consumer

needs.

6. Employee Welfare:

• Foster a safe and healthy work environment for all employees.

• Provide opportunities for professional growth and development through

training and skill enhancement programs.

7. Community Engagement:

• Engage with the local community through social responsibility initiatives

and support for local development projects.

• Promote awareness about dairy nutrition and the benefits of consuming

high-quality dairy products.

4
8. Transparency and Trust:

• Maintain transparency in all operations and build trust with consumers,

farmers, and stakeholders.

• Ensure ethical practices & compliance with all regulatory requirements.

By focusing on these goals, a Verka plant aims to contribute significantly to

the overall mission of MILKFED, promoting sustainable dairy development,

enhancing farmer livelihoods, and providing high-quality dairy products to

consumers.

5
 ORGANIZATIONAL STRUCTURE

The structure of Verka, under the Punjab State Cooperative Milk Producers'

Federation Limited (MILKFED), is designed to efficiently manage the various aspects

of dairy production, processing, and distribution. The organization typically includes

several key departments, each responsible for specific functions. Here is a general

overview of the organizational structure and departments of Verka:

1. Top Management:

• Managing Director: The top executive responsible for overall strategy,

management, and decision-making.

• Board of Directors: Provides governance and oversight, representing

the interests of member farmers.

2. Core Departments:

a. Procurement and Production:

• Milk Procurement Department: Manages the collection of milk from

dairy farmers, ensuring quality and timely payments.

• Production Department: Oversees the processing of milk into various

dairy products, ensuring efficiency and quality control.

• Quality Control Department: Ensures that all products meet the

required safety and quality standards through rigorous testing and

monitoring.

6
b. Technical and R&D:

• Technical Department: Handles the maintenance and operation of

machinery and equipment in the processing plants.

• Research & Development (R&D) Department:- Focuses on innovation,

developing new products, and improving existing processes.

c. Sales and Marketing:

• Sales Department: Manages the distribution of products, develops

sales strategies, and maintains relationships with distributors and

retailers.

• Marketing Department:- Handles advertising, branding, market

research, and consumer engagement to promote Verka products.

d. Finance and Accounts:

• Finance Department: Manages financial planning, budgeting, and

accounting.

• Accounts Department: Oversees billing, payments, and financial

reporting.

e. Human Resources:

• Human Resources (HR) Department: Manages recruitment, training,

employee welfare, and performance management.

f. Supply Chain and Logistics:

• Supply Chain Department:- Ensures the efficient procurement of raw

materials and supplies.

7
 • Logistics Department:- Manages the transportation and distribution of

products to various markets.

g. Legal and Compliance:

• Legal Department: Handles legal matters, compliance with

regulations, and risk management.

• Compliance Department: Ensures adherence to industry standards

and regulatory requirements.

h. Information Technology:

• IT Department: Manages the organization’s technological

infrastructure, including software, hardware, and data management

systems.

3. Supporting Departments:

i. Customer Service:

• Handles consumer inquiries, complaints and feedback to ensure

customer satisfaction.

j. Corporate Social Responsibility (CSR):

• Manages community development initiatives, sustainability programs,

and social responsibility projects.

Each department is headed by a manager or director who reports to the top

management, ensuring coordination and alignment with the organization's overall

goals and vision. This structure enables Verka to operate efficiently, maintain high

standards of quality, and support the welfare of dairy farmers and the community.

8
 PRODUCTS AND SERVICES

Verka Patiala, as part of the Punjab State Cooperative Milk Producers'

Federation Limited (MILKFED), offers a wide range of dairy products and services.

These products are known for their quality and are widely consumed in the region.

Here is a list of some of the key products and services offered by Verka Patiala:

PRODUCTS:

1. Milk:

• Full Cream Milk

• Toned Milk

• Double Toned Milk

• Skimmed Milk

2. Ghee:

• Pure Desi Ghee

3. Paneer:

• Fresh Paneer

4. Curd

• Fresh Curd (Dahi)

• Probiotic Curd

5. Lassi and Buttermilk:

• Sweet Lassi

• Salted Lassi

• Chach (Buttermilk)

6. Flavored Milk:

• Different flavors such as chocolate, strawberry, and cardamom

7. Kheer

• Ready-to-eat kheer
9
SERVICES:

1. Milk Collection and Processing:

• Efficient milk procurement from local dairy farmers.

• Processing of milk to produce various dairy products.

2. Quality Control:

• Ensuring high standards of quality and safety in all products through

rigorous testing.

3. Distribution and Supply Chain:

• Robust logistics network to ensure timely delivery of products to

retailers and consumers.

4. Farmer Support:

• Providing training and support to dairy farmers to enhance milk

production and quality.

• Ensuring fair prices and timely payments to farmers.

5. Customer Service:

• Handling consumer inquiries and feedback to improve products and

services.

6. Community Engagement:

• Participating in social responsibility initiatives to support local

communities.

Verka Patiala is committed to delivering high-quality dairy products while

supporting the welfare of local dairy farmers and contributing to the community.

10
 ABOUT MILK PRODUCTION AT VERKA

Different Functions performed in Dock Lab:

• Grading of incoming raw milk.

• Raw milk testing.

• Testing of outgoing past milk.

• Testing of processed milk stored in storage tank orsilo.

• Lassi testing.

• Dahitesting.

• Standardization of fluid milk.

• Checking of strength of detergent in create washer.

• Checking the weight, film thickness prints and length of the pouches.

• Checking the cleanliness of tankers after emptying and before filling milk.

• Testing of shelf life of milk for city supply.

Various tests are performed over milk in the RMRD labare:

1. Sensory Evaluation

2. Test of the detection of adulterants

3. Acidity

4. Fat

5. SNF

6. Protein

7. TS

8. MBRT test

11
 MILK HANDLING PRODUCT CAPACITIES –
MILK UNION PATIALA

City Supply of Market milk 60,000 Liters per day

Dahi 5 MT/day

Lassi 10 MT/day

Paneer 500 KGs per day

Kheer 1,000 KGs per day.

Sweetened Flavored Milk 25,000 Bottles / day

Cheese 1.8 MT/day

Total Milk Handling Capacity 1,60,000 Litres per day

MILK PASTEURIZER

Temp of pasteurized milk:

(a) for SMP manufacturing 72-78°C

(b) for city supply 75-78°C

Chilled milk temp Max 5°C

Chilled water inlet temp Max 1.5°C

Chilled water inlet pressure Min. 1.5 kg/sq cms

Flow rate of milk 10000 lit/hr.

Steam pressure Min 1.5-3.0 kg/sq cms

12
CREAM PASTEURIZERS

Pasteurized Cream Temp 85-88°c

Chilled cream temp Max. 10°C

Chilled water inlet temp Max. 1.5°C

Chilled water inlet pressure Max. 1.5kg/sq.cm.

Steam pressure Max. 1.5 – 3.0kg/sq.cm.

Flow rate of cream 2500 lit/hr.

HOMOGENIZATION

Homogenization is done only in case of preparation of sweetened flavoured milk or

reconstituted in this diary.

OPERATING PARAMETERS

Stage Temperature Pressure

1st Stage 50-60o C 2500psi

2nd Stage 50-60o C 500psi

PACKAGING OF MILK WITH FSS MACHINE

Number of FSS machines : 4 for 500ml (having 2 head each machine) And 1 for 6L

13
OPERATING FUNCTION OF FSS MACHINE

1. Film supplied from back position of the machine.

2. Shaping the film into cylindrical tubes.

3. Vertical sealing on the overlap using a vertical electrode.

4. Injecting & filling the liquid milk into the tubes.

5. Horizontal sealing by horizontal electrodes subsequently cutting to a

predetermined length.

6. Detaching the filling bags.

14
4 TYPES OF VARIANTS:

Nutritional
Standardized Full Cream Double
Information per Toned Milk
Milk Milk Toned Milk
100 ml

Energy value
72.0 87.0 58.0 46.0
(kcal)

Total Fat (g) 4.5 6.0 3.0 1.5

Saturated fat (g) 2.9 3.8 1.9 0.96

Trans fat (g) 0.0 0.0 0.0 0.0

Cholesterol (mg) 10.8 14.4 7.2 3.6

SNF 8.55 9 8.55 9

Total
Carbohydrates 4.8 5.1 4.8 5.1
(g)

Proteins (g) 3.0 3.15 3.0 3.15

Minerals (g) 0.7 0.75 0.7 0.75

Added Vitamin A
- - 77 77
(IU)

Added Vitamin D
- - 55 55
(IU)

15
CLEANING PARAMETERS

S. NO. EQUIPMENTS WASHING FREQUENCY

After every reception

1. Milk chillers pipelines CIP
and weekly

After every emptying

2. Raw milk storage silos CIP Full CIP
and weekly

3. In the filter sieve Manual cleaning After every reception

4. Dead end pipe fittings -Do- After every reception

5. Milk storage tank -Do- -Do-

6. Milk storage silos -Do- After every emptying

7. Milk chiller -Do- Once a month

CIP after 1 lot and

8. Pasteurizer plates CIP and manual manual after 6 months
by opening it

16
2. DAHI:

Indian curd is known as dahi, which is very popular, that fermented milk product all
over India in Punjab generally sour dahi is consumed. This diary plant follows the
FSSAI standard of dahi.

VARIANTS OF DAHI:

150g cup TM

200g cup TM

400g cup TM

500ml puch TM

1L pouch TM

5kg matka TM, DTM

15kg matka TM, DTM

EQUIPMENTS USED ARE

• Steam Jacketed Vat,

• Dahi pasteurizer

• Weighing Balance

• Incubation Chamber,

• Dahi Packaging Machine

• Cold store

17
a) Made from: Toned milk with min 3.0% fat and 10.0% And DTM with min 1.5%
fat and 10% SNF

b) Final product: Acidity – 0.8-0.9% LA, 3.0% fat and 10.0% SNF (Accounting
norm: 3.05% and 10.05% respectively) For DTM matka Fat 1.5%

c) Shelf life: 4 days (in "used-by" date)

COMPOSITION MAINTAINED BY THIS DAIRY PLANT

Fat 3.05%

Protein 3.2-3.4%

Acidity 0.8-1.0% LA

Taste Cream-sour

Flavour Acid

PACKING OF DAHI Polystyrene cups, pouches and matka.

18
 FLOW CHART OF DAHI PREPARATION

Pasteurization and Standardization


Storage at below 5oC


Heating of milk by PHE at 90oC for
10 minutes outlet temperature of milk
45-50oC homogenization at 2000 & 500 psi 

Inoculation Vat-culturing at 42-44oC or as per
Addition of DVS recommendation of supplier of culture
culture  Add 100 units / 1000 liter of milk. Mix well by keeping
the agitator "ON" for 10-15 minutes before filling starts


Pouch / Cup / Bulk filling, coding and sealing machine


CBXs / Crates

o

Incubatino at 42 to 44 C or as per recommendation of
supplier of culture till acidity reaches 0.60 0.02% L.A.


Blast cooling & Cold Storage till the product
temperature reaches less than 5oC & acidity
reaches 0.85%  0.05%.


Dispatch in insulated / Refrigerated van

19
3. LASSI:

Plain Lassi

• Made from: Dahi from standardize milk (fat=4.55% and SNF8.55%

Acidity=0.8-0.9% LA Dahi: Water=50:50)

• Final product: Acidity=0.4-0.5%, fat=2.25%(min), SNF=4.25%(min) and

TS=6.5%(min)

• Shelf life: 4 days (in "use by" date)

Sweet Lassi

• Made from: Dahi from standardize milk (fat=4.55% and SNF8.55%

Acidity=0.8-0.9% LA Dahi: Water=50:50)

• Sugar: 10%(4kg/can), flavour=kewra(6.25ml/100L)

• Final product: Fat=1.1%, SNF=2.1%, Acidity=0.4-0.5%, TS=6.55%(min)

• Shelf life: 4 days (now in "use by" date)

Masala Lassi

• Made from: Dahi from standardize milk (Acidity=0.8-0.9% and Dahi:

Water=50:50, salt=115g/40L, black salt=25g/40L, Masala lassi seasoning

• Final product: Acidity=0.4-0.5%, (fat=1.1%, SNF=2.1% and TS=3.2%

20
• Shelf life: 4 days (now in "use by" date)
Low Fat Lassi

• Made from: Dahi from standardize milk (Acidity=0.8-0.9% and Dahi:

Water=50:50, salt=115g/40L, black salt=25g/40L, Masala lassi seasoning

• Final product: Acidity=0.4-0.5%, (fat=1.1%, SNF=2.1% and TS=3.2%

• Shelf life: 4 days (now in "use by" date)

EQUIPMENTS AND UTILITIES REQUIRED:

1. Storage tank

2. Multi-purpose vat/storage tank

3. Heating with holding time of 10 minutes at 90o C

4. Milk chiller

5. Pouch packing machine

6. Shear pump

7. Cold storage to maintain less than 4o C

8. Pumps, valves and pipe lines

9. Chilled water (0-1o C)

10. Electricity

11. Voltage stabilizer

12. Soft water (hardness <10 ppm)

21
 FLOW CHART OF LASSI PREPARATION
Standardized and Pasteurized milk

   
Heating of milk by PHE at 90oC for 10 min
with outlet temperature of milk at 45-50oC

   
Inoculation of culture in MPST @ 100 units / 1000 liter of milk
at 43 1oC or as per recommendation of supplier of culture &
setting the dahi (acidity 0.80-0.90% L.A.)

   
Adding 15% (of dahi) pasteurized water & agitation with circulation
of chilled water in jacket & circulation through shear pump

   
Addition of remaining pasteurized chilled water (85%
For spiced lassi:
of dahi of plain lassi, 157% of dahi for low fat lassi,
spice powder and salt
@0.5-0.7% & 0.45%
of lassi resp
 156% of dahi for spiced lassi, 147% of dahi for sweet
lassi including water used for sugar syrup
preparation)

For Sweet lassi:

sugar @ 10% of lassi
   
Thermization at 65  2oC and chilling to 3-4oC

   
Storage Tank

   
Chiller

   
Pouch packing at <3o C

   
Cold storage at <4o C


    Dispatch in insulated / Refrigerated Van

22
 4. PANEER
Paneer is very popular indigenous milk product in north India mainly in Punjab
& Haryana. Traditionally Paneer is a variety of pressed channa, used for preparing
cooked vegetable dishes.

COMPOSITIONAL & OTHER STANDARDS

Fat Not <50% of dry mater basis

Moisture Not >70%

Texture Soft & spongy

Taste & flavour Pleasant

EQUIPMENTS USED

1. Steam jacketed vat

2. Trolleys

3. Sealing machine

4. Hoops

5. Machine for pressings

23
• Made from: fat=5%, SNF=8.65%

• Final product: fat=25-27%, fat=52%min (on dry basis), moisture=45-53%,

yield=16.5%

• Shelf life: 5 days (now in "use by" date)

COMPOSITIONAL & OTHER STANDARDS

Fat Not < 50% of dry mater basis

Moisture Not > 60%

Texture Soft & spongy

Taste & Flavour Pleasant

TPC NMT 50,000/gm

Coliform Count NMT 90/gm

24
 FLOW CHART OF PANEER MANUFACTURING

Pasteurization and Standardization: Fat

2.0%  0.05% & SNF 8.60%  0.05%

o

Heating by PHE 90 C & holding for 10 minutes
with outlet temperature 74 2oC
Citric Acid @ 0.18% 0.2%
in water (I % strength of citric
acid) at 75 2oC

Straining Vat for getting coagulum


Straining of coagulum & draining of whey


Hooping in Muslin cloth-lined hoops


Pressing at 6kg/cm2 for 10-12 minutes


Cutting


Cooling of paneer in Pasteurized chilled water
(At less than 10oC for minimum 90 to 120 minutes)


Shredding of Extra pieces
Cutting, Weighing and
Packing at less than 15oC  & Immerse in 80-90oC
water


Cold Storage (<4oC)


Dispatch

25
5. KHEER:
Kheer is also known as Basundi, is an Indian Dessert prepared by the partial
dehydration of whole milk in a karahi over fire together with sugar and usually rice or
occasionally semolina. it is very popular in Punjab and whole northern region.

• Made from:toned milk (fat=3.05%, SNF=8.55%)

• Final product: TS – 25-30%, recovery 76% (min)

• For 160kg milk taken:
• Sugar=8%=12.800kg
• Rice=4.5%=200kg
• Elaichi=0.07%=100g
• Recovery=76%(min)=122kg
• EQUIPMENTS USED
• Steam jacketed kettle
• Weighing balance
• Packaging
• Kheer is filled manually from hopper or conical vat and then capping
and sealing of kheer cups is done by packaging machine.

Sugar
Moisture Fat Protein Lactose Ash
(added)

74.3% 3.4% 4% 8.45% 1.41% 9%

26
 FLOW CHART OF KHEER PREPARATION

Pasteurization Standardized Milk (Fat 3.0% 

0.05% SNF 10.0% 0.05%) in kettle


Boiling for about 10 minutes with
continuous stirring and scrapping

Rice  Sorting & Washing 


Addition of Rice


Boiling with continuous stirring and scrapping
Sugar +
Grounded Green till it attains desired concentration or T.S.S.
Cardamom + (15-16%)
Sodium Benzoate

Gentle boiling with continuous stirring cum
scrapping is continued for about 10-15 min
till final concentration
(when TSS is around 24-25% as per
refractometer reading)


Plastic crates Transfer to double jacket hopper with facility
of cooling of product to 70 2oC


Kheer Filling Maching


Storage at <4oC


Packing in corrugated boxes


Dispatch in refrigerated / insulated vehicles

27
6. SFM (Sterilized Flavour Milk)

Ingredients Specifications:
Pasteurized Standardized Double Toned Milk which shall meet the following
specifications:
a) Fat 1.5% ± 0.05%,
b) SNF 9.0% ± 0.05%,
c) MBRT: min 6.00 hrs.
d) Phosphatase test: Negative
e) Acidity% (L.A.) max. 0.14
f) Creaming index: <10
g) Alcohol (70% v/v) test: Negative
Sugar: 6%
Colour: As specified in the table
Flavour: As specified in the table
Shelf life: Minimum 120 days from the date of packing when stored in a cool and dry
place.

Chemical Specifications:
PARAMETERS STANDARDS
Total carbohydrates % (Min) 11.10
Added Sugar % (Min) 6.0
Protein % (Min) 3.15
Total Fat % (Min) 1.5
Total T.S. (%) (Min) 16.5
Creaming Index <10
Total Flavours of SFM = 9
28
 Qty per Qty per
Name of the Name of Brand Name of Brand
S.No. 2000L of 2000L of
Product Flavour Name the colour Name
milk milk
IFF
1. Elachi Cardamom 570 ml no no no
(BUSH)
Lemon
Butter yellow IH 6597
IFF
2. Butter Scotch scotch 645ml colour made by 180gm
(BUSH)
flavour (INSE- bush
102)
Strawberry IS 5346
Strawberry IFF colour made by
3. Strawberry 785ml 30gm
flavour (BUSH) (INSE- Sun Food
127) Tech
Apple
green IH 8925
Pista chio IFF
4. Pista 785ml colour made by 180gm
olypia (BUSH)
(INSE-102 bush
& 133)
Coffee
5. Coffee Nestle 8500gm no no no
powder
Made by Caramel
IFF type IV
Chocolate brand
6. Chocolate (ABRAC 825ml Ammonia 10.50L
flavour supreme
Star sulphite
Branch) (150d)
Chocolate
Made by
brown
Sweet IFF IH 8962
colour
7. Badam almond (ABRAC 645ml made by 750gm
(INSE-
flavour Star bush
102, 122
Branch)
& 133)
Apple
Made by
green IH 8925
Thandai sona
8. Thandai 450ml colour made by 160gm
flavour rome
(INSE- bush
040815
102&133)
Made by
IFF
(Ginger
Ale bel
Lemon
Ginger Fast) 1600ml yellow IH 8925
Ginger & flavour &
9. + + colour made by 160gm
Honey Honey
(INSE- bush
Flavour Made by 375ml
IFF 102)
(ABRAC
Star
Brand)

29
 FLOW CHART FOR SFM PREPARATION
Pasteurization Standardized
Colour / Flavour / Coffee Homogenized Milk (Fat : 1.5 ±
as per SFM variant 0.05% and SNF: 9.0 ± 0.05%)
 Homogenization at 2000 & 500 psi

  

Mixing Tank / Vat
(60-65°C) 

   Sampling
Mixing for at least 30 minutes
Sugar

Cleaned & Inspected
bottles (inspected with Packing Machine Crown
magnifying glass) Cork
 
Iron Crate


Sterilizer
121°C for 15-17 minutes


Accelerated cooling


Sleeving and shrink wrapping


Packing in CBX's


Storage at <30°C


Dispatch

30
7. CHEESE

Raw cheese (Cheddar) and processed cheese are being manufactured by the plant.

Ingredient Specifications:-

Pasteurized Milk with Casein/Fat ration 0.68 to 0.72: The milk shall be prepared from
the fresh collection of raw milk which is pasteurized at 76 to 78 C/15 seconds with
following specification

a) Casein/ Fat Ratio: 0.68 to 0.72

b) Acidity % (as Lactic Acid) Max. 0.130,

c) Residual antibiotics: Absent

d) MBRT in hours: Min. 6:0 hours

e) Phosphatase test: Negative

f) Adulteration tests: Negative

DVS Culture: DVS culture As recommended by MilkFed

Rennet: Microbial origin

EQUIPMENT REQUIRED
Equipment Number Capacity
Cheese cooking Stephen 01 80kg
Kettle
Cekatainer sealing machine 01
Cheese vat 02 5000L & 4000L
Cheese press 04
Vacuum packaging machine 1 15 blocks per Hr
Cheese milling machine 1 3000 kg per Hr
Tin sealing machine 01

31
32
PROCESSED CHEESE

Recipe
Ingredient In kg or
Cheddar 50.00
Cheese Blend
Na-citrate 01 Zoha C 1kg
DSP 0.300 Zoha T 0.300
Citric acid 0.04
Sorbic acid 0.036
Nisin 0.024
Butter 1.00
Salt 0.350

Selection of blend: Blend is selected keeping in appropriate manner by blending

the cheese of different age group as under for best body, texture and flavour:-

Green cheese of age not more than one month: 1 block

Young cheese of age 2 months to 4 months: 2 block

Matured cheese of age 5 months and above: 1 block

This ratio may change from time to time due to availability of stock, but in that case
wise blend selection is done based on physical characteristic of available stock of
raw cheese.

33
34
Final Product:

Nutritional Information Per 100 g*

Energy Value (kcal) 350

Total fat (g) 25

Saturated fat (g) 16.25

Trans fat (g) 0.0

Cholesterol (mg) 60

Total carbohydrate (g) 6.3

Added sugar (g) 0.0

Protein (g) 25

Minerals (mg) 550

Vitamin A (IU) 1100

• Shelf life: 6 months (less than 8o C)

• Products of cheddar cheese: processed cheese, cheese spread, cheese
singles

PROCESSED CHEESE SPREAD

35
Recipe:

Ingredient In Kg

Cheddar cheese Blend 24.00

Na-citrate 0.90

DSP 0.30

Chakka 2.00

Sorbic Acid 0.36

Nisin 0.024

Butter or cream 10.00

Salt 0.30

GMS 0.15

Water 10.00

Butter: 80-82% fat or Cream: 58-60% fat

Primary packing: 200g cup

Secondary packing: corrugated boxes without holes

Nutritional Information Per 100 gm*

Energy value (kcal) 284

Total fat (g) 20.0

Saturated fat (g) 13.0

Trans fat (g) 0.0

Cholesterol (mg) 48.0

Total carbohydrate (g) 6.0

Added sugar (g) 0.0

Protein (g) 20.0

Minerals (mg) 500.0

36
37
8. Ghee Section

Ghee ranks as the largest produced milk product in our country.

Roughly 33% of total milk production of India is converted to Ghee.

The reasons lying beyond so large production of Ghee in India are :

• Very spoilage production in rural areas away from urban consuming centre.

• Rapid spoilage due to unfavourable climate condition throughout the year.

• Lack of all weather & refrigerated transport facilities.

• Long keeping quality under ordinary packaging & tropical storage condition.

• Market demand.

38
COMPOSITIONAL & OTHER STANDARDS OF GHEE MAINTAINED
BY THIS DAIRY

Flavor & color Pleasant & white or yellow

Total fat 99.7%

Moisture Max. 0.25%

F.F.A. (% Oleic Acid) Max. 0.03%

B.R. reading at 40o C 40-43

Bedouin test Negative

Peroxide value Max. 1

Sediment Absent

OPERATING PARAMETERS

Pre-melting temp (oC) 75-80

Cooking temp (oC) 105-112

batch time (hr.) Max. 4

Steam pressure in kettle (kg/sq.cm.) 2

Filteration muslin cloth

Clarification temp(oC) 95+/-5

Setting time (hr.) Min. 6

Ghee filling tank temp (oC) 43+/-5

39
40
TREATMENT OF GHEE RESIDUE

• Ghee residue is treated in vat with hot water at 50-60°C for at least 1 hr. to
obtain a layer of ghee at the top of hot water surface.

• Then chilled water is sprayed at 5-10°C 10-15min. & ghee is allowed to

solidity.

• Removing of treated ghee from the top of the water surface.

• Then 2nd washing is given as per above procedure.

• Sample of left over treated water is disposed of after testing for fat not more
than 0.1% to be drained.

• If fat > 0.1% then above procedure is repeated again

41
42
 QUALITY SECTION

COMPRISE OF DOCK LAB AT GROUNDFLOOR AND PRODUCT LAB AT FIRST

FLOOR.

LABORATORIES OF Q.A. SECTION:

• Main lab
• Instrument room
• Microbiology room
• Dock lab

DOCK LAB

• Grading of incoming raw milk.

• Raw milk testing.

• Testing of outgoing past milk

• Testing of processed milk stored in storage tank of silo.

• Cream testing

• Butter milk testing.

• Standardization of fluid milk.

• Testing of fat in ghee residue

• Checking of strength of detergent in can washer, can scrubber and crate

washer.

• Checking of cleanliness

• Checking of weight, film thickness, prints and length of pouches for city supply
milk.

• Testing of cold store pouches

• Testing of shelf life of milk of city supply.

43
CHEMICALS LAB

• Sensory evolution of milk products.

• Checking of the composition of milk products.

• Hardness and Cl content of water.

• Checking the quality of regents, packing materials glassware for testing etc.

• Checking the efficiency of wastewater treatment.

• Controlling the cleanliness of dairy equipment as well as overall sanitization of

the plant.

MICROBIOLOGICAL LAB

• Checking the bacteriological quality of various types of milk and milk products.

• Determine the types and number of micro flora in air, water and various dairy

equipment and pipelines etc.

• Testing of keeping quality of milk and milk products.

AGMARK LAB

• Checking the quality of ghee and white butter.

• Fat, acidity, moisture etc. for various products

• Weight and volume analysis.

44
TESTING INDIVIDUAL MILK PRODUCTS

FLUID MILK ANALYSIS

Sampling Of Milk Tanks

• Sampling of raw milk at MRD: The samples for each society are taken from
weighing bowl into 200ml bottles.

• Sampling of raw milk from chilling centres in tankers: Sampling is done after
through plungering by opening the upper lids of the tankers in a pan and
200ml sample bottle.

• Sampling of processed milk dispatched to other milk unions Sampling is done

after thorough plungering by opening the lids of tankers in a pan and 200ml
bottle. In case of concentrated milk sample is taken after 1 hr of filling.

• Sampling of chilled-raw or processed milk from tank and silos in 200ml plastic
bottles.

Testing of incoming Raw Milk

S.No. Name of test Comments

1. Fat Gerber method

2. SNF By lactometer

3. Acidity By titration against N/9 NaOH

4. Tests for adulterants By chemical method

Sugar

Salt

Urea

5. MBRT Temp. of water bath & time for

reduction should be observed

6. Total count (SPC) As per standards

45
SNF Test

Type of lactometer used: Quevenne

Temperature for testing: 15.5oC

Formula used: %SNF = CLR/4 + 0.2f + 0.29

We may use the correction factors too.

Fat Test

By Gerber method

TESTING FOR PACKAGED PASTEURIZED MILK

Test Observation Frequency

Organoleptic Normal Once a shift

Temperature 6-7oC Once a shift

Fat test As observed Once a lot

SNF test As observed Once a lot

Acidity 0.11-0.14% T.A. Once a lot

Phosphates test Negative Once a lot

Sediment test 0.05ml/50ml Once a lot

MBRT Min. 4 hrs Once a lot

Coliform and SPC As observed Not regularly

46
While packaging of milk continuous pouches are taken from testing the
following:

• Weight

• Temperature

• Leakage

• Drop test for sealing strength

• Dimensions

• Bursting strength

1. PANEER

S.NO. TEST OBSERVATION METHOD

1. Organoleptic (slow and fast) Normal Sensory evaluation

2. Fat test 50% Gerber

3. Total solid 45-50% IRMA

4. Microbiology As pre standard As pre standard

2. KHEER
S.NO. TEST OBSERVATION METHOD

1. Organoleptic (slow and fast) Normal Sensory evaluation

2. Fat test 3.4% Gerber

3. Total solid 25.36% Gravimetric

4. Microbiology As pre standard As pre standard

47
3. PROCESSED CHEESE

S.NO. TEST OBSERVATION METHOD

1. Organoleptic (slow and fast) Normal Sensory evaluation

2. Fat test 25% Gerber

3. Total solid 53(max)% Gravimetric

4. Microbiology As pre standard As pre standard

5. Protein Kjeldhal method

4. LASSI

S.NO. TEST OBSERVATION METHOD

1. Organoleptic (slow and fast) Normal Sensory evaluation

2. Fat test As pre standard Gerber

3. Total solid As pre standard Gravimetric

4. Microbiology As pre standard As pre standard

48
 PROCEDURE OF SOME COMMON LABORATORY TESTS

1. ACIDITY TEST:

• Take 10ml milk in beaker

• Add 10ml distilled water & 1ml phenolphthalein indicator

• Titrate with N/9 NaOH

• Each ml of titrate=% acidity

2. AMMONIUM COMPOUND DETECTION:

• Take 1ml milk in a test tube

• Add 2ml Nesslar's reagent (8g HgCl, 16g KI & 60g NaOH in 500ml
DW)

• Brown or dark yellow coloration is positive

3. FAT TEST:

• Take 10ml gerber acid (90-91% conc. H2SO4)

in a butyrometer

• Add slowly 10.75ml milk

• Add 1ml iso-amyl alcohol and

adjust the level with DW

• Cap butyrometer with lock stopper

• Centrifuge for about 5 minutes

at 1000-1200 rpm (for SFM-12 minutes)

• Take reading of fat%

49
4. SALT:

• Take 5ml of 0.1341% Silver Nitrate.

• Add 2-3 drops of 10% potassium

chromate & mix.

• Add 1ml milk & mix well.

• Yellowish coloration is positive

5. SNF (Solids Not Fat):

• Warm milk in lactometer jar at about

40°C and then cool it to 15.5 °C

• Immerse lactometer in jar and take

corrected lactometer reading (CLR)

• %SNF= CLR/4 +0.2*fat% + 0.29

6. SUGAR:

• Take 15ml milk, add 1ml conc. HCl

and pinch of resorcinol

• Place it in boiling water bath for

5 minute

• Reddish (rose red/ brick red)

coloration is sugar positive

50
7. TURBIDITY TEST:

• Take 20ml milk, add 4g ammonium sulphate and shake well

• Keep undisturbed for Smin and filter through whatman No-12

• Take 5 ml filtrate and keep it in boiling water bath

• Cool and see for turbidity, if any then it sterilization is not completed

8. UREA:

• Take 2ml milk in a test tube

• Add 2ml of DMAB solution (16% in

alcoholic solution containing 10ml
conc. HCT)

• Yellowish coloration is positive

51
 CHALLENGES FACED BY INTERNS AT VERKA

Certainly! Here’s a more natural version addressing the challenges interns

may face at Verka:

CHALLENGES FACED BY INTERNS AT VERKA:

1. Getting to Grips with Technical Processes:- Adjusting to the detailed

workings of dairy production, including learning how to operate specialized

machinery and equipment.

2. Ensuring High Quality Standards:- Learning to meet strict quality control

requirements, conducting precise tests, and following food safety regulations

closely.

3. Dealing with a Fast-Paced Environment:- Adapting to the quick turnaround

times in production schedules and the need to complete tasks and projects

promptly.

4. Collaborating Across Departments:- Working with teams from production,

quality assurance, and logistics to solve problems and achieve common goals

together.

5. Developing Problem-Solving Skills:- Learning how to identify and resolve

issues that arise during production, applying analytical thinking and practical

solutions with guidance.

6. Navigating Regulatory Compliance:- Understanding and complying with

strict industry regulations governing dairy production to ensure operations are

legally and ethically sound.

52
7. Improving Communication Skills:- Practicing clear & effective communication with

supervisors, colleagues, & stakeholders to ensure tasks are well-understood

and objectives are met efficiently.

8. Learning Project Management Skills:- Developing time management

abilities, prioritizing tasks effectively, and successfully executing projects

within deadlines while maintaining quality standards.

9. Engaging in Sustainability Efforts:- Participating in initiatives to promote

sustainable practices in dairy production, considering environmental impacts

and resource conservation in daily operations.

10. Integrating Feedback for Growth:- Actively seeking and incorporating

feedback from supervisors and peers to improve performance, enhance

learning, and contribute effectively to team goals.

These challenges provide interns with valuable experiences in technical

knowledge, teamwork, problem-solving, compliance, and communication, setting a

solid foundation for their future careers in the dairy industry and beyond.

53
 LEARNING EXPERIENCE FOR INTERNS AT VERKA

Interns at Verka can expect a rich learning experience that spans various

aspects of dairy production, management, and industry standards. Here's how

interns can benefit from their learning experience at Verka:

Learning Experience for Interns at Verka:

1. Technical Proficiency:- Hands-on Training: Engaging in practical learning

sessions to operate dairy processing equipment and machinery, gaining

proficiency in milk processing techniques. Quality Control: Participating in

quality assurance activities, conducting tests, and ensuring products meet

stringent safety and quality standards.

2. Operational Insight:- Production Processes: Understanding the entire

spectrum of dairy production, from milk collection to packaging, and learning

about efficient workflow management. Cross-Functional Collaboration:

Working alongside teams in production, quality assurance, and logistics to

experience collaborative problem-solving and project execution.

3. Regulatory Understanding:- Compliance Knowledge: Learning about industry

regulations and compliance requirements relevant to dairy production,

ensuring adherence to food safety and quality guidelines.

4. Professional Development:- Skill Enhancement: Developing essential skills

such as critical thinking, decision-making, and effective communication

through real-world tasks and responsibilities. Project Engagement:

54
 Contributing to projects that enhance operational efficiency, product quality, or

sustainability initiatives, gaining practical experience in project management.

5. Feedback and Mentorship:- Guidance and Support: Receiving mentorship

from experienced professionals, incorporating feedback to refine skills and

approaches, and fostering continuous improvement.

6. Industry Exposure:- Market Insights: Gaining insights into market trends,

consumer preferences, and competitive dynamics within the dairy industry

through market research and analysis.

7. Personal Growth:- Professional Ethics: Developing a strong foundation in

ethical practices and corporate responsibility, understanding the broader

impact of dairy production on community and environment.

By actively participating in these learning opportunities, interns at Verka can

acquire valuable skills, practical knowledge, and insights that prepare them for

successful careers in the dairy sector and beyond.

55
 REFLECTION

COMPARISON BETWEEN TRAINING AT VERKA AND

ACADEMIC KNOWLEDGE AT COLLEGE

1. Practical Exposure vs. Theoretical Knowledge:- Training at Verka Milk

Plant (Production and Laboratory):- The training provided hands-on

experience with the day-to-day operations in both the production section and

the laboratory. In the production section, I observed the entire milk processing

chain, including pasteurization, homogenization, packaging, and storage. In

the laboratory, I participated in quality control tests, microbiological

assessments, which are critical for ensuring the safety and quality of dairy

products. Specific tests included titratable acidity, fat content determination,

protein analysis, and microbiological testing for pathogens and spoilage

organisms.

Academic Knowledge at College:- College education primarily focused on

theoretical aspects, covering fundamental principles of dairy science, food

technology, microbiology, and chemistry. While laboratory sessions at college

provided basic training in analytical techniques, they lacked the real-world

application and complexity of tests performed in an industrial lab.

2. Problem-Solving and Decision-Making:- Training at Verka Milk Plant

(Production and Laboratory):- Real-time problem-solving and decision-making

were integral parts of the training. In the production section, I witnessed how

professionals address operational issues such as equipment malfunctions,

production bottlenecks, and quality deviations. In the laboratory, I learned how

to interpret test results and make decisions regarding product release or

further testing. This experience also involved troubleshooting test

discrepancies and ensuring compliance with quality standards.

56
 Academic Knowledge at College:- Problem-solving in college was often

theoretical, based on hypothetical scenarios presented in textbooks or case

studies. While this approach helped develop analytical skills and theoretical

problem-solving techniques, it lacked the immediacy and context of real-world

situations encountered during the training.

3. Technology and Equipment:- Training at Verka Milk Plant (Production and

Laboratory):- Exposure to state-of-the-art equipment and modern technology

used in both the production and laboratory settings was a significant

advantage of the training. Understanding the operation, maintenance, and

troubleshooting of machinery in the production section, as well as the use of

sophisticated analytical instruments in the laboratory (such as spectro-

photometers, pH meters, and microbial incubators), provided practical insights

that are crucial for a career in the dairy industry.

Academic Knowledge at College:- College laboratories and classrooms

offered exposure to basic equipment and simulations. While these provided

an understanding of the underlying principles and basic operations, they did

not fully capture the scale and complexity of the equipment used in an actual

milk plant.

4. Industry Standards and Compliance:- Training at Verka Milk Plant

(Production and Laboratory):- The training included detailed exposure to

industry standards, regulatory compliance, and quality assurance protocols.

Understanding the stringent requirements for hygiene, safety, and quality

control in a live environment was invaluable. In the laboratory, I learned how

to adhere to standard operating procedures and regulatory guidelines for

testing and documentation, ensuring all processes met industry standards.

57
 Academic Knowledge at College:- Academic courses covered regulatory

frameworks and standards theoretically, but lacked the practical enforcement

and application aspects. The emphasis was on understanding the laws and

guidelines rather than implementing them in a real-world setting.

5. Professional Networking and Collaboration:- Training at Verka Milk Plant

(Production and Laboratory):- Interacting with industry professionals,

supervisors, and peers provided opportunities for networking and learning

from experienced individuals. Collaborative projects and teamwork in both the

production section and laboratory enhanced my communication and

interpersonal skills. Engaging with professionals allowed me to understand

the importance of teamwork and effective communication in achieving

operational excellence and quality assurance.

Academic Knowledge at College:- College provided a platform for academic

collaboration and networking with peers and professors. However, the

professional networking opportunities were limited compared to those

available during the training at the plant.

6. Skills Acquired:- Training at Verka Milk Plant (Production and Laboratory):-

• In-depth understanding of milk processing techniques and equipment.

• Proficiency in conducting lab tests such as titratable acidity, fat content

determination, protein analysis, and microbiological testing.

• Ability to interpret lab results and make informed decisions based on data.

• Skills in troubleshooting and maintaining laboratory and production

equipment.

• Familiarity with quality control procedures and regulatory compliance.

• Enhanced problem-solving, decision-making, and critical thinking abilities.

• Improved communication, teamwork, and professional networking skills.

58
Academic Knowledge at College:-

• Strong theoretical foundation in dairy science, food technology, microbiology,

and chemistry.

• Basic laboratory skills and understanding of analytical techniques.

• Development of analytical and critical thinking abilities.

• Exposure to academic research methodologies and scientific writing.

In conclusion, the training at Verka Milk Plant, particularly in the production

section and laboratory, complemented my academic knowledge by providing

practical experience and industry exposure. The hands-on training bridged the gap

between theoretical concepts learned in college and their real-world applications,

enhancing my overall understanding and preparedness for a career in the dairy

industry.

59
 ADVICE FOR FUTURE INTERNS

To future interns at Verka, as you embark on your internship journey, I offer

the following advice:

• Be open-minded and eager to learn. Verka offers a wealth of knowledge and

experience, so absorb as much as you can.

• Be proactive and take initiative. Don't wait for tasks to be assigned - seek out
opportunities to contribute and grow.

• Build relationships with your colleagues and supervisors. They are a valuable
resource and can provide guidance and support throughout your internship.

• Embrace challenges and view them as opportunities for growth. You will face
obstacles, but it's how you overcome them that matters.

• Keep a positive attitude and be flexible. Be willing to adapt to changing

circumstances and priorities.

• Take advantage of opportunities to learn about the dairy industry and Verka's
operations. Ask questions, attend meetings, and seek out training and
development opportunities.

• Finally, enjoy your time at Verka! It's a unique and rewarding experience that
will shape your future.

60
 CONCLUSION

REFLECTION ON HOW THE INTERNSHIP HAS IMPACTED MY

CAREER, GOALS AND ASPIRATIONS

The internship at Verka Patiala has been a transformative experience that has

significantly impacted my career goals and aspirations. Working in the dairy industry

has given me hands-on experience and exposure to the operational aspects of a

large-scale organization. I have gained valuable skills in teamwork, communication,

and problem-solving, which have boosted my confidence and prepared me for a

career in this field.

Specifically, my experience at Verka Patiala has:

• Deepened my understanding of the dairy industry and its nuances

• Developed my skills in data analysis and report writing

• Taught me the importance of quality control and customer satisfaction

• Exposed me to the challenges and opportunities in the industry

This internship has reinforced my desire to pursue a career in the dairy

industry, and I now aspire to take on leadership roles and contribute to the growth

and development of the industry. I am grateful for the opportunity to have worked

with such a talented and dedicated team and am confident that the skills and

knowledge gained will benefit me in my future endeavors.

******** ********

61