A REPORT OF INTERNSHIP TRAINING (1).pdf

ACKNKNOWLEGEMENT
I wish to give my heartful acknowledgement to Aavin Industry Ambattur for
providing me with a wonderful environment to do my internship here for 7
days.
Firstly, I would like to thank my mentor Mrs Devasena - Assistant
Professor-Plant Breeding and Genetics.
I would like to express my gratitude to Mr Jayakumar (Deputy General
Manager) of the Aavin Production Diary Ambattur.
Then, I wish to place my sincere thanks to My Professors and Faculty
members of the Department of Agriculture Sciences. Karunya Institute of
Technology and Sciences.
I wish to pen my heartful gratitude to Mr Dev (Quality Control Lab), Mr
Karthik (boiling unit), Mr Manikandan (boiling unit), and Mr Raju (Engineer),
Aavin Production Diary Ambattur for their concerned help, sensible
information and special supplements to the Aavin production diary.

A REPORT OF INTERNSHIP TRAINING
AT
AAVIN DAIRY COMPANY
Plot No 29 & 30, Manikka Vinaykar Koil street, Ambattur,
Chennai - 600053
By
Karunya Institute of Technology and
Sciences
School Of Agricultural Sciences
(B.Sc. (Hons) Agriculture)
Karunya Nagar, Coimbatore, Tamil Nadu 641114
Submitted By
S. GOWTHAM
(URK20AC1297)
OCTOBER - 2023

INTRODUCTION
Milk is a nutrient rich food that provides many
nutrients relative to the Calories Consumed milk
is delicious as a beverage and can be used as a
base or other drinks.
The milk of domesticated animals is also an
important food source for humans. Most milk
Consumed in Western countries is from cows,
other important sources include sheep, goats,
buffalo, and camels. Milk is essentially an
emulsion of fat and protein in water, along with
dissolved sugar, minerals (including calcium and
Phosphorous) and vitamins, particularly vitamin B complex. Commercially
processed cow’s milk is commonly enriched with vitamins A and D.
Many countries require pasteurization to protect against naturally occurring and
artificially introduced microorganisms. Cooling further prevents spoilage
(sourcing and curdling). Fat Rom whole milk (about 3.5% fat content) can be
removed in a separator to produce cream and leave low-fat milk (1-2 fat) or
skim milk (0.5% fat). Milk is usually homogenized, forced Under high pressure
through small openings to distribute the fat evenly. It may also be Condensed,
evaporated, or dehydrated for preservation and ease of transport. Other dairy
products include butter, cheese, and yoghurt.
World Wide:
June 1 World Milk Day by FAO = food and agricultural organization. [t gives to
children to Promote the growth of their muscles, bones, teeth, and brain
Pediatricians & Nutritionist Agree that the balanced with a proportion of the
necessary carbohydrates & proteins moreover, the high content of vitamin D in
milk is a key component to milk bone structure, bone recovery and bone health.
In Addition, maintain the health of the teeth.

The Day provides an opportunity to focus attention on milk and raise awareness
of dairy’s part in healthy diets, responsible food production, and supporting
livelihoods and communities. This is supported by FAO data showing that more
than one billion people's livelihoods are supported by the dairy sector and that
dairy is consumed by more than six billion people globally. The fact that many
countries choose to do this on the same day lends additional importance to
individual national celebrations and shows that milk is a global food.
Demand for dairy products in the region has more than tripled since 1980 and
despite the spectacular growth in production, production has lagged behind
demand in many countries.
As a result, dependency on the importation of milk and dairy products has
increased and, with the recent global increase in prices for dairy products, the
cost of imports has surged.
Around 80 per cent of milk in Asia is produced by smallholder farmers. In
addition, there are tens of millions of traders and dairy entrepreneurs — small
and large — involved in the dairy sector.
Some countries in the developing world have a long tradition of milk production,
and milk or its products have an important role in the diet. Other countries have
established significant dairy production only recently.
Most of the former countries are located in the Mediterranean and Near East,
the Indian subcontinent, the savannah regions of West Africa, the highlands of
East Africa and Paris of South and Central America. Countries without a long
tradition of dairy production are in Southeast Asia (including China) and tropical
regions with high ambient temperatures and humidity.
Rank Countries Production (metric
tons)
1. India 186,143,000
2. United States 98,646,000
3. Pakistan 45,623,000
4. Brazil 35,539,000
5. China 31,592,000
6. Russia 31,527,000

Dairying in India:
Today, India is "The Oyster’ of the global dairy industry. It offers opportunities to
Entrepreneurs worldwide, who wish to capitalize on one of the world's largest
and fastest-growing markets for milk and milk products.
India is ranked 1st in milk production contributing 23 per cent of global milk
production. Milk production in the country has grown at a compound annual
growth rate of about 6.2 per cent to reach 209.96 million tonnes in 2020-21 from
146.31 million tonnes in 2014-15.
India's dairy sector is expected to triple its production in the next 10 years given
Expanding potential for export to Europe and the West. Moreover, with WTO
regulations Expected to come into force in coming years all the developed
countries which are among the big exporters.
India has the world's largest dairy herd with over 300 million bovines, producing
over 187 million tonnes of milk. India is first among all countries in both
production and consumption of milk. Most of the milk is domestically consumed,
though a small fraction is also exported. Dairy plays a significant part in
numerous aspects of Indian society, including cuisine, religion, culture, and the
economy.
Dairying in Tamil Nadu:
Years Estimate in Tonnes
2017 – 2018 7,742
2018 – 2019 8,362
2019 - 2020 8,759
2020 - 2021 9,790
2021 - 2022 10,107

COMPANY OUTLINE
The dairy development was established in 1958 in Tamil Nadu. The
administration and statuary controls over all the milk cooperatives in the state
were transferred to the dairy development department on 1.8.1965. The
commissioner for milk production and dairy development was made as the
functional register under the Tamil Nādu Cooperative Societies Act With the
adoption of a new pattern in the state of Tamil Nādu. Tamil Nādu co - operative
Milk Producers Federation Limited was registered in the state of 1st February
1981. Mil
The commercial activities of the department such as milk procurement, chilling,
processing, packing and sale of milk to the consumer etc. hitherto dealt with by
the Tamil Nadu Dairy Development Cooperation Limited, were transferred to
the newly registered Tamil Nadu Co-operative Milk Producers Federation
Limited popularly known as Aavin. Chennai metro has four dairies. Milk
procurement, processing and distribution are being attended by the district
union in the respective areas.
In the wake of liberalization policy, private dairies have also entered into the
field of the honourable chief minister of Tamil Nadu high priority has been given
to improving the performance of milk co-operatives by adopting a symmetric
approach and proper strategy in milk co-operatives.
The cattle population in India is approximately 15% of the total cattle population
in the world. India stood No.1 position in milk production. Tamil Nadu is one of
the leading.
states in. The milk production in Tamil Nadu per day is 145.88 lakh Liters

Milk is the single largest agricultural commodity by value contributing 5 percent
of the national economy. Dairying has become an important secondary source of
income for millions of rural families and has assumed the most important role in
providing employment and income generation opportunities mainly for women
and marginal farmers.
Dairying plays an important role in the socio-economic development of rural
households in the country. The major share of the milk in the country is
produced by small, marginal farmers and landless labourers. Small land-based
encourages the farmers to practice dairying as an occupation subsidiary to
agriculture.
Income from agriculture is seasonal, whereas dairying provides year-round
income and generates gainful employment in the rural sector. The drivers of
demand for milk in India are population growth, urbanisation and increasing per
capita income. The dairy sector is therefore an important vehicle for inclusive
development in the country.
OBJECTIVES:
TCMPF is a Cooperative Apex Body in the State of Tamil Nadu representing
organizations of milk producers’ and implementing all round dairy development
activities to achieve the following objectives:
• To ensure an assured and remunerative market around the year for the
milk produced by the farmer members.
• To make available quality milk and value-added dairy products to
consumers.
• To build & and develop village-level institutions as cooperative model units
to manage the dairy activities.
• To ensure the provision of inputs for milk production, processing facilities
and dissemination of know-how.
• To facilitate rural development by providing opportunities for self-
employment at the village level, preventing migration to urban areas, and
introducing a cash economy and opportunity for a sustained income.

The philosophy of dairy development is to eliminate middlemen and organize
institutions to be owned and managed by the milk producers themselves,
employing professionals. To sum it up, every activity of TCMPF revolves around
meeting one basic objective: “Achieve economies of scale to ensure maximum
returns to the milk producers, at the same time facilitate wholesome milk at a
reasonable price to urban consumers”.
STRATEGIES:
• Facilitating the active performance of the primary societies and
transforming the defunct societies into functional societies.
• Developing necessary facilities at primary and union levels for the benefit
of milk producers.
• Imparting skills among the target group.
• Imparting extension education to the milk producers on the milk testing
process to strengthen clean milk production at the village level.
• Planning and implementing various schemes of State and Central
Government to achieve the best in milk production, processing and
marketing.
• Increasing the handling capacity of district-level dairies to meet the
requirements.
• Establishing new parlours, and sales points and developing the retail units.
• Formation of new milk routes, consumer societies and increasing the sale
of milk cards.
DAIRY DEVELOPMENT DEPARTMENT:
Vested with the powers of Registrar in discharging the statutory functions under
the provisions of the Tamil Nadu Co-operative Societies Act, 1983 (TNCS Act) and
Tamil Nadu Co-operative Societies Rules, 1988 (TNCS Rules).
The head of the department is the
Director of Milk Production and Dairy
Development (DMPDD). The DMPDD is
also functioning as the ex-officio
Managing Director of the Tamil Nadu
Cooperative Milk Producers Federation
(TCMPF) and as the Registrar of all the 3
tier milk co-operatives. The director is

TAMIL NADU COOPERATIVE MILK PRODUCERS’ FEDERATION LIMITED
(TCMPF):
The Tamil Nadu Co-operative Milk Producers’ Federation Limited (TCMPF) is the
apex body at the State level in the 3-tier pattern wherein all the District Co-
operative Milk Producers’ Unions in the State are members.
TCMPF was registered as a Cooperative society under the Tamil Nadu Co-
operative Societies Act and Rules. It was started on 01.02.1981 by taking over all
the commercial activities such as milk procurement, processing, packing and sale
of milk and milk products to the consumers. Previously the above subjects were
handled by the Tamil Nadu Dairy Development Corporation. The administrative
office of TCMPF has been functioning from the new corporate office building at
Nandanam since 20.06.2018.
Dairy plants of TCMPF Ltd.,
1. Central Diary – Madhavaram Milk Colony
2. Ambattur – Diary
3. Sholinganallur Diary
4. Products Diary – Ambattur
5. Dairy cum product plant (DCPP) – Tiruvannamalai
Central Dairy at Madhavaram Milk Colony is the first dairy plant in Tamil Nadu of
the Dairy Development Department.
Sholinganallur Dairy (III Dairy) is the first-ever automated dairy established in
South India in 1996.
Purpose of DCPP - to convert the surplus milk available with the District Unions
into Butter and Skimmed Milk Powder.
The above-mentioned dairy plants are governed as a Federation as they are in
full control by Chief Minister M.K Stalin.
The rest of the presented milk plants are represented by that particular district
councillor which is called Unions of Federation

DISTRICT UNIONS OF FEDERATIONS:
There are about 17 district co-operative milk producers’ unions functioning in
Tamil Nadu covering 30 districts. They are:
➢ Coimbatore Union
➢ Cuddalore Union
➢ Dharmapuri Union
➢ Dindigul Union
➢ Erode Union
➢ Kallakurichi Union
➢ Kanjeepuram Tiruvallur Union
➢ Kanyakumari Union
➢ Karur Union
➢ Krishnagiri Union
➢ Madurai Union
➢ Namakal Union
➢ Nilgiris Union
➢ Pudukkottai Union
➢ Salem Union
➢ Sivagangai Union
➢ Thanjavur Union
FUNCTIONS OF CO-OPERATIVE MILK PRODUCERS’ UNION:
➢ Establishment of chilling centres.
➢ Formation of new milk routes to collect milk produced by the
members of the societies.
➢ Collections of milk from societies are processed, and packed in
modern dairy.
➢ Supply of quality milk.
➢ Fixation of procurement and selling price of milk.
➢ Supply of inputs to the members of the societies.

Collection of milk collected by village of societies of farmers. The milk is collected
from many villages. The milkers give their milk through dairy form situated on
their village. Therefore, both societies and milk givers can earn money with some
profits. The collection of milk which is directly got from the milk-giver is known
as the "Raw Milk". The milk can be collected in the morning and evening,
The perishable nature of milk increases the storage and transportation problems
in developing village where access to electricity is challenging. Handling raw milk
from the farm to the dairy processing plant requires a cold chain to preserve its
quality. In a large dairy farming system in developed village,
Milk is immediately cooled and stored in a refrigerated tank during the milking.
In a small-scale system, investing in a cooling tank at the farm level is unrealistic
and financially unfeasible. Farmers have only two choices, transporting and
supplying a milk collection center or selling directly to the urban market or
households as raw milk.
Establishing a milk collection center requires a building, an investment in a
cooling tank, a connection to electricity, which runs the cooling system, and a
few milk-testing materials and products. Each model also depends on who
owned and managed these milk collection centers.
The milk is collected from many villages. The milker gives their milk through
dairy from situation on their village. Therefore, both societies and milk givers can
earn money with some profits. The collection of milk which is directly gets from
the milk giver is known as the raw milk. The milk can be collected at morning and
evening.
To collecting all milk from farmers to measures the milk the raw milk arrives at
the dairy in insulated road tankers. The milk must be kept well chilled, free from
air and treated as gently as possible.
For example, tanks should be well filled to prevent the milk from sloshing around
in the container.
HOW MILK IS COLLECTED

For the Ambattur unit, the milk is mostly transported from the 32 districts such
as Coimbatore, Salem, Erode, Dharmapuri, Madurai, and Tiruvannamalai.
At the initial stage in the process is a cow feeding on grass in a field. Twice a day,
the cows are taken from the pasture to a milking facility where they are milked
by an automated milking machine. The milk is collected and kept in the Co-
operative Society then later it is taken to the district BMC (Bulk Milk Coolers)
where the Fat and SMF (Solid Milk fat) are measured and noted. The milk is
stored in a cool storage.
Milk is stored in a great variety of storage tanks, first near villages as Bulk milk
cooling units, then transported by Road Tankers and then to Raw Milk Storage
tanks in dairy plants.
To maintain the initial quality of milk and to improve the quality of milk by
avoiding long-time transportation to Chilling Centres/Dairies, Bulk Milk Coolers
(BMC) have been installed at the village level for immediate chilling of milk. At
present, there are 356 BMCs with a chilling capacity of 15.94 llpd (Lakh Litres Per
Day).
Milk cooperatives have played a key role in the growth of the dairy sector in the
country. As the milk cooperative movement took root and spread across the
country, India transformed from a milk-deficit nation to the largest producer of
milk in the world.
The capacity of the bulk tank truck is 30,000 litres and if it is a small tank truck, it
is a 15,000-capacity. The tanker lorry is constructed in a way where it can
withstand milk at very low temperatures and doesn’t lead to spoilation. If the
milk is sent at 5°C then the temperature of milk remains the same till it reaches
the depot.
TRANSPORTATION

Milk is been Pumped Out 4 containers of Acid, Lye, Hot water, Caustic soda
RECEIVING MILK AT PRODUCTION UNIT
Immediately after the vehicle approaches the Aavin depot a sample of Raw milk
is collected in 60 litre container and sent to the Quality Control Lab to check the
fat and SNF percentage is the same as the one recorded at BMC. After the tests,
it is approved all the tests the milk from the container is pumped to the nearby
silo kept at the Aavin collection depot at Ambattur.
There are 8 Silos and the first three are for storing Raw milk after the approval of
test results. The Raw milk that reaches the depot as raw milk will have fat at
4% and SNF at 8.0%. The SNF percentage increases in winter and lowers in
summer. The remaining silos from 4 to 10 are processed milk. From 1 to 6, the
silo capacity is 60,000 litres and from 7 to 10 it is 1 lakh litre capacity.
Weekly once there will be silo cleaning with Acid, Lye, and Hot water in the
morning from 3:30 to 5:30 pm. The acid used here is Nitric acid.

MILK PROCESSING UNIT
DIARY PROCESSING:
The milk collected from the chilling centres is brought to the dairy and kept to
assess the quality. Some of the types of milk viz., standardised milk, high fat, and
high protein milk, are being produced for the requirements of the consumers;
the surplus fat is converted into ghee. The high-fat and high-protein milk are
packed in 200ml, 250ml, 500ml and 1000ml sachets. In the dairy, milk. Ghee, ice-
cream flavoured milk, rose milk, butter milk etc., are being manufactured and
marketed.
HOMOGENISATION:
Homogenization is a process that reduces the size of fat globules by forcing
pressurized hot milk through small whole causing turbulence, the breakup of the
larger fact globules so that they remain suspended rather than separating in a
cream layer at the top homogenization affects the development of
atherosclerosis, coronary, heart diseases, milk allergy, diabetes. The
homogenisation machine used here is from Buffalo Company where the milk is
pumped at a pressure wt of 2500kg.
Before the milk passes to the homogenization machine the milk is at a
temperature of 60°C. The milk fat quality is calculated so if there is less fat some
amount of butter is added at this temperature to the milk and sent for
homogenization so the mixed butter doesn’t float above the milk.
There are three sections inside the processing unit. where the milk from the
homogenization machine moves to the next section at a temperature of 75 –
80°C. Where it is cooled and stored at any silo above 4 as processed milk.
After storing the processed milk at the silo, a sample test is taken for the quality
test for Fat and SNF. If they approve the required quantity, the milk is sent to the
packaging unit. If they don’t approve the milk is again sent to processing to
correct the quantity of the milk. That will be either reducing or increasing the fat
or SNF by adding butter or milk powder.

Pasteurization:
It is a process by which the disease-causing bacteria in the milk are destroyed
without loss in its nutritive values. The milk is boiled at 60°C for thirty minutes
and cooled quickly. Whatever the method is used for the preservation of food,
cleanliness and general sanitary conditions are important. Before pasteurization,
milk is homogenized to separate the solids (fat) from the liquid, which ends
within the pasteurized milk having a whiter look as compared to raw milk
Pasteurization destroys 100% of pathogenic bacteria, yeast and mould and 95%
to 99% of other bacteria.
Types of milk:
1. Full Crèam Milk:
Full cream milk, also called whole milk is usually given to children,
teenagers, and bodybuilders This milk is called so because it contains all the
milk fat without adding or removing anything. It is collected from the dairy
herd and it undergoes various processing techniques like pasteurized ion to
kill potentially harmful bacteria before it reaches the general public. One
glass would generally contain 3.5% milk, which provides about 150
calories. Full cream milk is also creamier and full of flavour.
This is further divided into 2 types:
Whole Standardized milk:
In this type, the fat is said to be at a minimum of 3.5%
Whole Homogenized milk:
Fat globules are broken down and made to spread throughout the milk to
prevent the formation of the creamy layer at the top.
Single Toned milk:
Adding skimmed milk powder and water to whole milk makes single-toned milk.
It has about 3% fat and minimizes the body's absorption of cholesterol from the
milk. It contains almost the same nutrition as whole milk except the fat-soluble
vitamins. One glass of toned milk provides around 120 calories.

Skimmed milk:
Skimmed milk has 0.3% to 0.1% fat content. Though skimmed milk contains all
the nutrients found in whole milk like the vitamins and minerals, it gives you just
half the calories of full cream milk (around 80 calories per glass of milk). It
contains slightly more calcium than whole milk and even lower levels of fat-
soluble vitamins. Particularly vitamin A, as this is lost when the fat is removed.
Colour Indication and Composition of Milk
Aavin Blue milk packet:
Homogenized pasteurized STANDARDIZED MILK with 4.5 % Fat and 8.5% SNF
Content. Homogenized pasteurized full cream milk with Min. 6.0% fat and 9.0
SNF content. Pasteurized toned milk with 3.0% fat and 8.5% SNF.
Aavin Green milk packet:
Homogenized pasteurized STANDARDIZED MILK with 3.5% fat and 8.5% SNF
content.
Aavin Orange milk packet:
Homogenized pasteurized full cream milk with 6.0% fat and 8.5% SNF content.
Aavin Delite milk packets:
Aavin Delite to be sold at 30 Rs per 500ml pack, contains 3.5% fat and 8.5% SNF.
Added vitamins A and D.
Percentage of milk in milk:

QUALITY CONTROL TESTS
In the Quality Control Lab of Aavin, 19 tests are been conducted on milk at
various stages.
Platform Test:
➢ Temperature
➢ Organoleptic
Chemical Analysis:
➢ CLOT On boiling test
➢ Acidity
➢ FAT test
➢ SNF test
➢ Homogenisation Efficiency
➢ Phosphate Test
Microbial Analysis:
➢ Keeping Quality test
➢ MBR test
➢ Coliform test
➢ Standard Plate Count test
➢ Antibiotic Residue Test
Adulteration Test:
➢ Urea Detection
➢ Neutralizer test
➢ Starch Ceral Flours Detection test
➢ Sugar and Glucose test
➢ Hydrogen Peroxide test
➢ Salt Detection
Immediately when raw milk sample is collected from bulk containers,
➢ COB test
➢ MRBT test
Is conducted to check whether the milk is suitable for the diary or not. If the Raw

Packaging and cool storage
The processed milk is stored at Silo 4 to 10 that is been passed through the test
taken by the lab and is sent to the storage tank above the packaging unit. The
milk is transferred into 4 different pipes and storage tanks as there are 4
different types of milk.
The packaging of milk is an important aspect of protecting, carrying, and
marketing, to sustain its freshness and convenience. Various types of packaging
are used for packaging milk, such as bags. The packaging trends vary concerning
the place.
A cold room is a type of refrigeration chamber or insulated space designed to
maintain an artificially generated temperature or range of temperatures, Cold
rooms are used for storing temperature-sensitive, perishable items, such as food
items and pharmaceutical products like vaccines. Cold rooms can vary in size
from very small walk-in rooms to very large warehouse storage. Here the milk is
stored at 3-4°C.

DISPATCH
Finished products must be properly protected during shipping. The type of
vehicle or containers required depends on the type of product and the
conditions under which it has to be transported.
Unless you take effective control measures, finished products may become
contaminated during shipping or may not reach their destination in a suitable
condition for consumption. This can happen even when proper hygiene control
measures were taken when you made the product.
➢ Protecting product from potential sources of contamination.
➢ Separating products from non-compatible products on the same load
➢ Protecting product from damage that could make it unsuitable for
consumption.
➢ Keeping the product at the right temperature prevents the growth of
spoilage micro-organisms that may shorten the shelf life of the product.
TRANSPORT VEHICLES:
The vehicles and containers used to transport food should be kept clean and in
good condition. If you use the same vehicle or container for transporting
different foods or for transporting non-food products, it must be effectively
cleaned and disinfected (if necessary) between loads.
CONCLUSION:
“A STUDY ON THE OBSERVATIONAL OF MILK PRODUCTION AT AMBATTUR AAVIN
INDUSTRY”. Thank you for this wonderful opportunity by Aavin to do my
internship here at the Ambattur Aavin facility. I was indeed able to learn more
deep and practical knowledge about milk procurement. I’m grateful to have met
wonderful departmental staff who explained to me about each unit and how
they function etc.

A REPORT OF INTERNSHIP TRAINING (1).pdf

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