Production Department

Milk procurement

Milk is raw material for the dairy industry; therefore development potential of a dairy industry depends largely on the efficient milk procurement system. Looking to the present status of competitive era success of any dairy plant lies in winning the confidence of milk producers through fair dealing for achieving an assured, regular & better quality of the milk at reasonable market price, following is latest system of milk procurement implemented:

A) Direct Milk Procurement system from milk producers (Village level collection centers)

B) Operational structure of village level collection centers attached to the chilling centers through milk assembling centers.

C) Disposal of milk prom chilling centers to the main factory.

Milk Procurement standard & pricing policy

The price to be paid for raw milk is decided in relation to the prices offered by others competitive agencies in the area. The price for the milk purchase is standardized keeping base of Fat percentages & SNF percentages of milk i.e. 6.5% fat & 8.8% SNF for calculation of Buffalo milk & for Cow milk above 3% & below 5% fat & 8.5% as standard SNF. If the received deviates from the above standard of Buffalo & Cow milk, the penalty is imposed.

Tests conducted at the chilling center

Tests Purpose

Temperature High temp. indicates poor quality

Organoleptic Taste, appearances, odour

Alcohol test Stability of the milk

Clot on boiling (COB) Heat stability

Acidity (before & after boiling)

Sugar Should be negative

Starch Should be negative

Salt Should be negative

Vegetable fat Absent

Fat% This forms the basis of payments

SNF% This forms the basis of payments

Production Department

Raw Milk Reception Dock (RMRD)

Process section

Ghee section

Formulation section/MDX

Evaporator & dryer section

Packaging section

Dry blending section

Raw milk reception dock (RMRD)

It is the name given to the platform where the milk is received at factory site. Before receiving the milk, it is sampled, graded, tested for adulterants and fat, SNF. Then accepted milk is stored at Raw milk Tank (RMT).

As the tanker arrives at the dock, milk sample is drawn by QA people. On the basis of test report, the milk is being rejected or accepted and if accepted, then production people are asked to unload the tanker. The milk is unloaded using a pump, which helps in filling into any of the RMT. If the temp. of the milk is above 4-5c, then milk is passed through a chiller to maintain its temp. up to desired level.

Technical specification of the equipments used are as follows:

1) Centrifugal pump

Make : Laurd Knudsen maskin faric ltd.Capacity : 20,000 kg/ hrMotor : 3.5 H.P.

2) Chiller

Make : Afla LavalCapacity : 20,000 kg/hrNo of plates : 86

Schematic Diagram of Raw milk reception dock

Pump Chiller.

Tanker

RMT RMT

Process section

Technical specification of Equipments in Process Section

1) Milk Chiller

Make : Afla LavalCapacity : 20,000 kg/hrNo of plates : 86

2) Pasteurizer

Make : Afla LavalCapacity : 5,000 kg/hrHeating medium : Hot waterChilling medium : chilled waterNo. of plates : chilling section- 22 Regeneration 1-58

Regeneration 2-82 Heating section-25

Temp. programmed: 4-40-74-48-12-4c

3) Cream separator

Make : Afla LavalCapacity : 5,000 kg/hrNo. discs : 118+ top/bottomRPM : 5200Motor : 7.5H.P., 1445 RPM, 50Hz.

4) Cream concentrator

Make : Afla LavalCapacity : 5,000 kg/hrNo. discs : 118+ top/bottomRPM : 5200Motor : 7.5H.P.,1445 RPM, 50Hz.

5) Raw milk Tank

Make : IDMC LTD.

Capacity : 25,000litPosition : Horizontal with vertical agitator

6) Pasteurized milk tank

Make : IDMC LTD.Capacity : 25,000litPosition : Horizontal with vertical agitator

7) FCBT

Make : Alfa laval.Capacity : 110lit

8) Cream tank

Make : Industrial Aiders ltd.Capacity : 500lit

9) Concentrated tank


10)Butter milk tank


11)CIP tank

Make : IDMC ltd.Capacity : 2500litNos : 3

The major function performed in the process section is to separate the fat from the raw milk for ghee manufacture. Standardized milk is prepared by using the skim milk & whole milk in required ratios.

Flow diagram

Milk received

Weighing, sampling, testing, grading, unloading

Milk chiller

RMT

Pasteurization (82c/ no hold)

Cream separator

Cream

Ghee section

Roto pump

Concentrator cream balance tank

Cream concentrator

Skim milk

Mixed with whole milk for standardization

Skim milk storage tank

Chilling section of Pasteurizer

Unit operation in the Process section

1) Chilling of raw milk

Inform the utility department to open the chill water supply. Open the chill water line & maintain the temperature of chilling section. Check all the line valves whether they are in right position or not. After the temperature is achieved, feed the milk to the chiller through

the pump.

Schematic diagram of chilling of milk

Milk Chiller Storage tank

Pump

2) Pasteurization

Pasteurization is a process of heating of milk to such a temp. and for such periods of time as are required to destroy any pathogens which may be present. Pasteurization method used here is HTST method i.e. High temperature short time. Milk is heated to around 82c for no hold.

Procedure followed

Check the valves position in line so as to adjust any change if required. Open the steam line & maintain the temp. of heating section. Open the chilled water & maintain the temp. of heating section. After the temp is achieved, feed the milk to pasteurizer.

RMTRMT

Flow diagram of Pasteurization

FCBT

Pump

Regeneration 1

Duplex filter

Regeneration 2

Clarifier / separator

Heating section

Regeneration 1

Chilling sectionPMT

Regeneration 2

Schematic diagram of pasteurization

FCBT

PUMP

Chilling section R1 R2 Heating section

Duplex filter

Cream separator/Clarifier

Milk line

Pasteurized milk line

Chilled milk line

Final storage tank

3) Cream separation

Cream is separated from milk using the centrifugal force in the cream separator. Centrifugal separator is preferred to the other methods because it offers shaving in time, space & costs. The separator consists of closely spaced cone shaped discs in the bowl, which rotate with bowl. The no. of discs are 120, placed one above another. When centrifugal force is applied skim milk being heavier is thrown towards the periphery & the cream being lighter is collected in the center. The crew is adjusted to get the desired percentages of fat in the cream.

Operation

Through clean all the parts of the separator. Assemble all the parts of the separator & bowl. Assure all parts of the separator are tightened properly. Start the motor & allow it to gain its max. speed. Start the milk feed. Adjust cream screw to get the desired percentage of fat in the cream. Collect the cream in the in the cream tank & skim milk followed by

pasteurization in the storage tank.

Shutdown procedure

When all the milk has been separated, run water in place of the milk for 5 mins.

Stop the water inflow. Switch off the motor & let it come to rest.

Lubrication

All the bearing point of the cream separator except the ball bearing point of the separator on the motor side are splash lubricated from a central oil bath. Fill the gear chamber with oil through the bore for oil & fill until the level is slightly above the center of the watch glass.

Cream concentrator

Cream concentrator work on the same principle as the cream separator. All the procedure & working is also similar.

Ghee section

In this section, ghee is prepared from the concentrated cream and same is filled in the tins or refill pack.

Flow diagram for the manufacturing of the ghee

Concentrate cream (80% fat)

Ghee kettle (106 -108c)

Steam (3 Kg/cm2)

Filtration through 100 mesh

Residue Filtered ghee

Residue treatment

Drained Ghee kettle

Ghee

Cold room for granulation (22c/ 48 hrs.)

Packed in tins or refill pack

Filling tank

Clarifier (65-70c)

Settling tank (75c)

Residue

Ghee preparation procedure

The concentrate cream from the process section is continuously transferred to the ghee kettle tank & simultaneously, the steam valve is opened at a steam pressure of 2.5-3 Kg/cm2. as the temp. rises in the ghee kettle, the cream starts boiling. To avoid the burning of ghee, the steam pressure is maintained as such so that temp. may not be excessive heating at any point.

When all the moisture from the cream is driven out then the temp. of the mix rises abruptly. At this point, the ghee is said to be fully prepared. Also, the heating at this stage is to be carefully controlled. The end point is indicated by the appearance of effervescence, which is much finer than first, accompanied by the browning of the curd particles.

Now the steam is closed & the ghee is left it is in the kettle for about 2-3hrs. so that the temp. of the ghee comes down & ghee residue settles down. After this the ghee is passed through the 100-mesh filter & pumped to the settling tank. In the settling tank, finer particles, which are still present in the ghee, are settled. The ghee is kept in settling tank for about 2-3 hrs. Now the suppertant part i.e. sediment cleared ghee is passed through the clarifier. In the clarifier, the ghee is filtered from the finer sediment particles using the centrifugal force. The residue being heavier is thrown towards periphery & the being lighter is collected in the center.

This clarified ghee is then collected in the filling tank until they are filled in the retail packs. Then melt no is timely changed on the ghee packs as per the Agmark specification. The manufacturing date & the other specification are printed on the shippers.

After filling the into the retail packs in the liquid state, these are kept in the kept in at 22c for proper granulation. These packs are kept in the granulation room for at least 48 hrs. The granular form assumed by the ghee is primarily due to certain glycerides of higher melting saturated fatty acids, especially palmatic & stearic,

Technical specification of equipments used in the ghee section

Ghee kettle

Make : Industrial Aiders ltd.Capacity : 15,00litPosition : Vertical Numbers : 3

Settling tank

Make : Industrial Aiders ltd.Capacity : 1200litPosition : Vertical Numbers : 2

Filling Tank

Make : Industrial Aiders ltd.Capacity : 2600litPosition : Vertical Numbers : 3

One litre ghee filling

Make : RallatainerCapacity : 12 per min.

Fivteen kg tin filling


Tanker unloading tank


CIP procedure in the process section & ghee section

CIP( clean in place) means that rinsing water & detergent solution are circulated trough tanks, pipes & process lines without the equipments being dismantled. For CIP purpose there are 3 tanks located outside of the process section.

CIP procedure

As the milk flow is about to complete, run water after the milk behind it. Then rinse with warm water for about 8 mins. Circulate the caustic solution from caustic solution tank for about 20

mins at 75c. Rinse out caustic solution with water. Circulate nitric acid solution for about 10 mins at 70c. Rinse out acid solution. Flash with hot water at 75c for about 5 mins.

Line diagram for CIP

Duplex Filter

P=Process sectionG=Ghee SectionE=Evaporating Sec.

Caustic tank

P G E P G E

Hot water tank

Acid tank

Formulation Section/MDX

Technical specification f the equipments used

1) Sugar tank

Make : SSP ltd.Capacity : 1000lit.Number : 2

2) MDX tank Make : SSP ltd.

Capacity : 1600lit.Number : 2

3) Formulation tank


4) Corn oil tank


As per the production planning the raw material of the batches are received from the store. Appropriate quantity of raw materials mixed together to form a final batch, which is feed to the evaporator followed by drying. During formulation there are different parameters, which must be strictly followed. It is most important steps of production of any product. Any error in formulation stage may lead to faulty production. There are specific temp. for the specific raw materials.

Schematic diagram of Formulation section

Sugar Sugar MDX MDX Tank Tank Tank Tank Steam Steam

Pump

Formulation Formulation Tank Tank

Chiller

Final batch storage tank (WT1)

Final batch storage tank (WT2)

Evaporator & Dryer Section

Evaporator

An evaporator consists of a heat exchanger capable of boiling the solution & a device to separate the vapour phase from the boiling liquid. One of the most simplest evaporator is a steam jacketed kettle open to the atmosphere. In Industrial operation the equipment is usually arranged for continuous operation, the exchange surface is vastly increased, boiling is more violent & vapour evolution is rapid.

There are three evaporator of different capacity in Wockhardt Ltd., fabricated by SSP Ltd. the respective capacities of the evaporator are 3000Kg/hr, 2000Kg/hr, 1500Kg/hr. All the three evaporator are triple effect falling film type.

The capacity of the evaporator means the kg of the water evapourized per hr. It is given by the falling equation:

Q=U*ATWhere, Q=rate of heat transfer.

U=overall heat transfer coefficient. A=area of heat transfer surface. T=temperature different

Triple Effect Falling Evaporator

The evaporating process requires a great deal of energy in the form of heat. Therefore the steam consumption is the cost determining factor in evaporator. In multiple effect evaporator the vapour from one Calendria is used as the heating medium for another. In this way steam consumption

Equipments used in the triple effect falling film Evaporator

TVR, Holding Tube, High Heater, DSI Surface Condenser, Vacuum Pump, Concentrate Pump, Feed Pump Condensate Pump, CIP Pump, CIP Tank, Balance Tank

Some Important Units In The Evaporator

Thermal Vapour recompressor (TVR)

High steam economy is obtained by recompression of the vapour generated from the boiling milk. This done by adding energy to the vapour by a steam jet. In TVR a part of the whole of the vapour from the first effect is compressed with live steam & these vapour again reused in the first effect. TVR consist of convergent nozzle which ejects steam at a high speed. The velocity of the mixture of vapour & live steam is reduced in the diffuser & therefore the pressure & temp. are increased, making the suitable as

heating medium in the Calendria. As a result of using TVR is beneficial in respect of the cost of steam consumption.

High Heater

High heater is used to heat the milk to temperature of above 90c. The high heater is changed after every four hour of operation to minimize the scaling & thus maintaining the efficiency of the plant.

Direct Steam Injector (DSI)

DSI is that part of the evaporator where the steam is directly injected into the liquid milk. Here the temp. of the milk is raised to about 93c. This is done to decrease the bacterial load by destroying any type of the pathogens or spores present in the product since they cannot be killed by the mild heat treatment.

Surface Condenser

Condenser is a special heat transfer devices used to liquefy by removing their latent heat. In a surface condenser, the vapour is condensed by a cooling medium. This is a shell & tube type heat exchanger.

Vacuum Pump

A pump that takes suction at a pressure below atmospheric & discharge against atmospheric pressure is called a vacuum pump. As a result of the vacuum applied by using the vacuum pump the boiling point of the product decreases, thus in the less steam consumption & thereby reducing the cost.

Starting the Evaporator Plant

Manually check all the value weather they are in right position or not. Open the main valve of the steam header. Open the seal water valve. Switch on the vacuum pump. Switch on the feed pump. Switch on the concentrate pump respectively. Open the steam valve of the High heater, DSI & TVR. Adjust the temperature. Switch on the condensate pump. When desired temp. reaches in the High heater, DSI, TVR & Calendria set the

Plant in automatic condition. Feed the milk in place of water.

Stopping the Evaporator Plant followed by CIP

When milk is finished water valve is opened. Water pushes the milk. When all milk is pushed, drain the water for few mins. Add caustic (NaOH) in the balance tank so that the strength of the solution is

maintained to 1 to 2 percents. Stop the vacuum pump and cooling water inlet valve is also closed. When the temperature in all the particular portions is reached to 75 to 80c

circulate for 45 mins. Flash the plant with normal water. Close the steam valve of High heater, DSI & TVR. Switch off the condensate pump. Switch off the concentrate pump respectively. Switch off the feed pump. Manually check the distributor plate, DSI, Calendria tubes

Milk flow in evaporator

Standardized chilled milk (4-6c)



Preheater 1 (50c)

Preheater 2 (60c)

Preheater 3 (70c)

Continue to next page

Direct steam injector

Holding tube

High heater

Flash vessel

Calendria 1(1st part)

Calendria 1 (2nd part)

Dryer

Concentrate tank

Vapour separator 2

Vapour separator 1

Vapour separator 3





Vapour flow diagram

Condensate flow diagram

Flash vessel Vapour separator 1

Vacuum pump

Condenser

Calendria 3

Calendria 2

Calendria 1

TVR

Calendria 2

1)

2) Steam flow diagram

Trouble shooting in Evaporator

Calendria 3

Condenser

Calendria 2

Boiler house

Condensate

Condensate pump

Drain

DSI(2Kg/cm2)

Main steam header

High heater

(2Kg/cm2)

TVR(2Kg/cm2)

Sl No.

Trouble Cause/ Remedy

1 Desired concentration not being achieved, even if vacuum plant in the plant is good

Total solids in feed lower. Flow rate may be on the higher than

recommended. Steam pressure to the TVR is low. Calendria tubes would have developed thick

scales or chocking would have taken place. Cooling water supply is erratic. Water leakage to the system through the CIP

circuit of High Heater or vapour separator bodies.2 Lower vacuum in the

plant. Air leakage in the plant Cooling water supply to the condenser not

adequate. Chocking in the Calendria tubes. Condensate built in the bodies. Air vent line to the Calendrias not set proper.

3 Reduced flow of product.

Any of the product pumps giving problem, the stuffing boxes & shaft seals to be checked.

Chocking of the distribution plate & Calendria tubes.

4 Condensate coming out white in colour.

Build up milk in any of the vapour separator or holding tube due failure of one of the product pumps.

The flow product is not uniform in the plant, resulting higher level in any of the bodies, resulting sucking of the product vapour droplets from the vapour separator.

Leakage in the tubes of higher heater or calendrias.

5 Heat exchange tube getting frequent chocked.

Higher temp. in the bodies. Higher concentration in the product than

recommended. Acidity of the milk used is high.

6 Cooling water out let temp. high.

Inadequate supply of the cooling water due to 1. Air lock of cooling water supply pump.2. Chocking of the suction strainer cooling

water pump.3. Inlet valve of cooling water pump not

adequately opened. Higher temp. in the bodies, due to lower steam

pressure or fouling in the tubes in calendrias.

Spray Drying

Spray drying is the transformation of the feed from a fluid state into a dried particles form by spraying in the fee into a hot drying medium.

Principle

The basic principle of the spray drying consists in atomizing the milk, preferable preheated & concentrated, to form a spray of very minute droplets (fog like mist) which are directed into a large, suitable designed drying chamber where they mix intimately with a current of hot air. Owing to their large surface area, the milk particles surrender their moisture practically instantaneously & dry to a fine powder, which is removed continuously.

The system of the spray drying involves large & complicated plant & requires a tall building for the housing. The initial cost & energy consumption is very high. The process is economical only when large quantities of milk are handled.

Technical specification of the 500kg Dryer plant

Type : Tall formCapacity : 500 kg water evaporation/hr Make : SSP Pvt. Ltd.

Designed parameters

Initial solids : 48%Water evaporation rate : 500 Kg/hr. Feed rate : 985 Kg/hr.

Operating parameter

Powder out put rate : 485 kg/hrFinal moisture : 2.5%Drying air inlet temp. : 190cDrying air outlet temp. : 90cPowder conveying temp. : 15c

Flow diagram of spray drying

Concentrate tank

Cyclone separator

Hot air incorporation Drying chamber

Nozzle

Duplex filter

Centrifugal pump

Homogenizer

Plate heat exchanger

High pressure pump

Bagging

Shifter

Conveying cyclone separator

Powder conveying duct

Main rotary valve

Roots blower

Blow through valve

Rotary valve

Starting the Dryer Plant

Manually check the whole plant. Switch on the blower, all the rotary valve, shifters etc. Fire the air pack. Start the exhaust fan. Start the supply fan. When outlet temp. reach to 100c feed the water. When outlet temp. decreases feed the milk.

Stopping the Dryer Plant

When milk is finished start water in place milk. When outlet temp. decreases stop the air pack. Stop the supply fan. Stop the exhaust fan. Stop the blower, all the rotary valve, shifters etc.

Cleaning of the plant

Dry cleaning. Wet cleaning.

Dry cleaning of the drier was done with the help of a scraper & a long broom. Casuals are lowered inside the chamber by means of a lift mounted on the dryer. The powder sticking to the walls were removed by the rubbing action of the broom & then by the scraper. The powder thus collected is called Chamber Sweep Powder (CSP)

Wet cleaning is always proceeded by dry cleaning. Wet cleaning was done by washing off the remaining powder by the water & rubbing action of the broom. Wet cleaning removed the traces of the powder particles from the drier & exposed the polished metal.

Trouble shooting in Dyer

Sl Trouble Cause/ Remedy

No.1 Excessive moisture

content in the powder.

Relative moisture content in the outlet air is too high-outlet air temp. to be lowered.

Humidity in the cooling air was too high-dehumidifier should be used.

2 Reduced evaporation capacity

Too low inlet air temp.-air heater & oil burner to be checked.

Reduced flow of inlet hot air. Intake excess of cold air, than desired.

3 Burnt particles. Improper milk spray. Improper stopping of the operation. Stickages in chamber. Inlet air sucking milk powder particles (particles). Low moisture content/ high inlet air temp. Hot air filter torn off.

4 Lower solubility Index.

Concentrate pre-heating not done. More residence time of product with high

accumulative heat treatment. Drying condition not proper adjusted. Poor quality of milk.

5 Lower or higher bulk density

More TS in concentrate would give higher bulk density & vice-versa.

Increased air pressure reduces bulk density & vice-versa

DRY BLENDING SECTION

This is the most critical section of the whole plant, because the final formulation of the some product is done here. The base product are dry blended with vitamin, mineral salt, refine sugar, oil, lactose, Soya protein isolate, and various type of cereal extract etc, to achieve the final composition of the product according to the BOM. In this operation highly hygienic condition is maintained, because the final product is obtained from mechanical dry blender where no heating is done.

There is two-type blender in Wockhardt Ltd1. Octablender2. Screw type oil mixing blender

1) OCTABLENDER: The octablender is consist of

1. 4000 Lt octablender chamber2. Double bag dump hopper3. Product conveying pipe

4. Vacuum pump 5. Bag filter

Working principle:

Firstly check that the whole blending area is properly cleaned or not.Then switch on the AHU of the room, and maintain RH and temperature as per BOM.After that alcohol mopping is done to sanitize the wet cleaned blender and hopper.Then the product-conveying pipe is attached with the blending chamber.Then the vacuum pump is started, and the vacuum is created through the bag filter, for that the conveying product is separated from the air through bag filter.After completing the whole dumping, the product conveying line is disconnected with the blending chamber and then the blender is allowed to revolving.After specific time of revolving the blender is stopped and product is collected in the bean.The whole operation is done very carefully and hygienically, because any contamination can spoil the whole product. For that after every batch of product completing the whole blender and blending section is wet cleaned.

2. SCREW TYPE OIL MIXING BLENDER: This is relatively small blender and it is specially use for oil mixing. It is consist of

1. 600 lit blending chamber2. A screw conveyor3. A motor

Working principle:

Firstly the product is dumped directly in blending chamber.Then the motor is switched on for proper mixing of product with screw conveyer.Then the calculated amount of oil is added in the product.After proper mixing of product, the final product is collected in the bin.

Specification of blender:

Octablender

Make : AAHAN Engineers Pvt Ltd

Capacity : 4000 lit

Type : O.B.

Oil mixing blender

Make : Gransons Nauta

Type : X

Capacity : 600 lit

Motor S : 5 H.P.

Motor A : .5 H.P

Model : DB XO600R

Job No : W/NX-6/B

PACKAGING SECTION

Its packing department plays a major part in the sales and growth of any industry. There are many factors, which consumers take into consideration before buying any product, but the main three criteria are, Appearance Color Packing formIf a product is packed in a eye catching packet, then certainly there are better chances of sales of that product because the ultimate judge of the product are the consumer and they have to be genuinely lured to make them buy the product.

The packing form plays more than 50% part in the sales of the product. Hence, the most sophisticated packing machinery is used to make the product presentable.

There are two types of packing machinery used at Wockhardt Ltd.

1. Tin packing (Delta line)2. Pouch packing (Rovema)

The powder is packed only when the quality assurance department approves it. The packing of powder is done as per the market demand. The powder is first packed in to tins or pouch pack, then these pouch are filled in the cartons. These tins or carton are then packed in the shippers and dispatched for further distribution to the depots.

Pouch filling machine:

In this machine firstly the foil role is set in the back side of the machine, then the foil is pulled by the vacuum belt and simultaneously it is bend and form like pouch.Then it is vertically sealed and after that the bottom is sealed.After that the powder is filled into the pouch from the hopper, and then top of the pouch is sealed.In this type of packing the oxygen content is kept under critical control as this may lead to the spoilage of the powder during further storage periods.

MAKE : ROVEMA CAPACITY : 5 to 105 bags per minute

Before starting the machine, the nitrogen pressure and the top and bottom seal temperature is checked.

Tin packing line:

The tin packing line is the assembly of different parts. These different parts may be subdivided as:

1. Depalletiser2. Hot air blower3. UV tunnel4. Spoon inserter5. Delta filling line6. Clincher7. Terlet nitrogen filler8. Double seamer9. Domino ink jet printer10.Over capper

Depalletiser:Here, the tins are unloaded from the pallet and placed on the magnetic conveyor which brings them down on the hot air blower.

Hot air blower: Before coming to the hot air blower the tins are passed trough a vacuum machine where the dust and dart particle are removed, after that the tins are semi sterilized by hot air.

UV tunnel: This is the tunnel through which when the tins are passed; they are totally sterilized by using the ultra violet rays. Since, these ultra violet rays are harmful for the microorganism that may be present in the tin, they render it completely safe for powder packing.

Spoon inserter: Here UV rays firstly sterilize the spoon and then inserting in the tins. The total system is automatic and no one tin can pass without the spoon.

Delta filling line:Here the powder is filled in the tins with the help of vaccum system. According to the size of tin, the vaccum setting is done and as per the vaccum drawn, the powder quantity is filled into the tin.

Clincher:Here, the lead is loosely clinched onto the tin, so that when the tin will pass through the Terlate Nitrogen filler, the powder may not spill out of the tin and simultaneously the gas will removed and insert easily.

Terlet Nitrogen filler:This is the main part of the whole packing line. Here, the oxygen is extracted out of the tin and nitrogen is filled in its place. Hence this is a modified atmosphere packing form. The capacity of this filler is 0 to 84 tins per minute.

Seamer:Here the double seaming of the tins or the final sealing is done. This is the permanent seal present at the bottom.

Printer:This is a Dominos made ink-jet printer which is used to print the manufacturing date, expiry date, batch number, and the time of packing of the product.

Over capper:It is used to fit the over caps made of plastic on the lid of the tin. It is use in very few product.

The remaining packing line is GEI make and imported form U.K. The whole operation of the packing line is PLC controlled. Every subsequent operation in the line is inter locked with the previous operation so that if there is fault at any stage, then the tin will not removed further as the signal will not be transmitted further.

Depalletise

Hot air blower

UV-Tunnel

Scoop Inserter

DELTAFILLER

Garvens C/W

Under WeightTin

Over CapperPrinter Seamer

NitrogenFiller

UV-Light

LidConveyer

Clincher

Engineering Department

Refrigeration Plant

Boiler Plant

DM Plant

Nitrogen Plant

ETP Plant

REFRIGERATION

VAPOUR COMPRESSION REFRIGERATION SYSTEM :

This is most common method of refrigeration used now a day. The principle advantage of using this type of refrigeration system is smaller size unit and less running cost.

Principle: In this refrigeration system instead of air, vapours like ammonia, carbon di oxide, sulphur di oxide, freon are used as a working fluids. The system works on reverse carnot cycle. The refrigerant alternatively undergoes change in phase from liquid to vapour and vise versa, while changing it phase from liquid to vapour it will absorbe heat from material to be cooled and give up while changing its phase from vapour to liquid. A liquid refrigerant such as Ammonia is used for refrigerant purpose.

A vapour compression system consist of an evaporator to contain the boiling liquid refrigerant, a compressor to pump the refrigerant vapour from the low pressure to high pressure side of the system and to control the pressure with in the evaporator, and a condenser for removing the heat from the refrigerant gas so that it may be returned to the liquid form. Also; there is a receiver for storing the liquid refrigerant under high pressure, and a expansion valve for controlling the rate of flow of liquid refrigerant between high and low pressure side.

Working Of The System

The water is chilled from 4.5 c to 1.5 c in ice bank tank by refrigerant vapour from the surge drum outlet is sucked and compressed to the condensing pressure by reciprocating compressor. The compressed gas is then condensed at 40 c temperature in shell and tube type condenser. The condensing of gas is being carried out in condenser on the shell side by the circulation of cooling water in the tube side. The condensed liquid ammonia is then collected in the liquid receiver by means of gravity flow from condenser outlet to the receiver. From the receiver, liquid gets expanded by means of expansion valve and enters into Ice Bank Tank coil where the evaporation takes place. Hence the refrigeration cycle completed in this way.

REFRIGERATION CYCLE

Condenser

Evaporator

Compresor

Expansion Valve

RECEIVER

SPICIFICATION FOR THE REFRI GERATION PLANT:

PLANT CAPACITY : 154 TR

NO. OF COMPRESSOR : THREE

CAPASITY OF EACH COMPRESSOR : 77.3 TR

REFRIGERANT : AMMONIA

CONDENSING TEMPERATURE : 40ºC

EVAPORATING TEMPERATURE : -10ºC

SPEED OF COMPRESSOR : 650

COOLING WATER FLOW RATE ACROSS EACH CONDENCER : 71m3/ hr

EQUIPMENT SPECIFICATION:

1. RECIPROCATING COMPRESSOR:

NUMBER : ThreeMAKE : KirloskarMODEL : KC-6CAPACITY : 77TRSPEED : 650 RPM

2. OIL SEPARATOR:

NUMBER : One per compressorsMAKE : KirloskarMODLE : TYPE 80

3. CONDENSER:

NUMBER : TwoTYPE : Shell and TubeMAKE : Radiant engineersNUMBER OF PASS : FourCOOLING WATER FLOW :71m3/hr

4.RECEIVER:NUMBER : ONEDIAMETER : 915 mmLENGTH : 5000 mmMAKE : M.B.Industries

5.AGITATOR:NUMBER : SixTYPE : VerticalMAKE :ABBMOTOR : 10 HP

6.COOLING TOWER:NUMBER : FourTYPE : Natural DraftCAPASITY : 74 m3/hrMAKE : Armech

7.AIR PURGER:NUMBER : OneTYPE : ManualMAKE : M.B.Industries

8.AIR HANDLING UNIT (Packing and Blending Room):NUMBER : TwoTYPE : Chilled water coilAIR QUANTY : 4000m3/hrMAKE :ABB

9.AIR HANDLING UNIT (Ghee Granulation Room):NUMBER : OneTYPE : Chilled water coilAIR QUANTITY : 4000 m3/hrMAKE : ABB

10. AIR HANDLING UNIT (BAG ROOM):NUMBER : OneTYPE : Chilled water coilAIR QUANTY : 12000 m3/hrMAKE: ABB

DEMINERALISED WATER PLANT

The natural water contains solid, liquid and gaseous impurities and therefore this water cannot be used for the generation of stem in the boilers. The impurities present in water should be removed before its use in the stem generation.

IMPURITIES IN WATER:

The impurities in the feed water are classified as below.1.UNDISSOLVED AND SUSPENDED SOLID MATTER:The different types of undissolved and suspended solid matter in the raw water are classified as below.

Turbidity and sediment due to mud, sand etc.Sodium and potassium salts.Chlorides.IronManganese.Silica.

2. DISSOLVED SALTS AND MINERALS:Different types of dissolved salts and minerals are classified as under.

Calcium and Magnesium salts present in water in the form of carbonates, bicarbonates, sulphates, and chlorides.

3.DISSOLVED GASES:OxygenCarbon di oxideNitrogen

4. OTHER MATERIAL:Free Mineral AcidOil

PROPERTIES OF RAW WATER:

HARDNESS OF WATER

The hardness of water is defined as the amount of calcium carbonate in the water, and it is referred in parts per millon (pip) or grains per gallon.

The hardness of water is due to the presence of different salts of calcium and magnesium in the form of carbonates, bicarbonates, sulphates, and chlorides.

The hardness of water is classified as temporary and permanent hardness.

TEMPORARY HARDNESS:

The temporary hardness of water is caused due to the presence of bicarbonates of calcium and magnesium and can be removed by simple boiling. The boiling converts the soluble bicarbonates into less soluble carbonates, which can be removed by, simply blow down method.

PARMANENT HARDNESS:

The permanent hardness of the water is caused due to the presence of chlorides, sulphates and nitrates of calcium and magnesium. These salts cannot be removed just by boiling because they form a hard scale on the heating surfaces.

DEMINERALISATION:

The demineralization of water is carried out by using Ion- Exchange resins. Ion-Exchange resins are porous materials, which contain an inert base attached to which free ions are further attached. These ions are free to move about within the resin structure, and can be replaced by other ions of the same type from a surrounding solution.

The ion-exchange resins are made of cross linked polystyrene. Cation resins are made of sulphonated polystyrene. The sulphonic acid group SO3H contributes the free hydrogen ion H+ available for exchange and can be represented in an equation as RH.

The anion exchanger is similarly made but it is chloromethylated and then aminated. The final product is quandary ammonium compound and this can be represented in an euation as RCL.

WATER TREATMENT:

The water supply should be free form suspended matters, oil, algae, slime, and heavy metals such as iron aluminum, etc. The ion-exchange resins act as filters, but their deionizing ability and capacity is highly affected if the water is dirty.

Firstly the water is passed through cation unit. After this the water is passed through Degasser where the carbonic acid formed during the cation unit is splited into carbon di oxide and water and thus removed. The Degasser tower consists of the gravles and the air is blown through it. This air carries with it carbon-di oxide and escape through a opening at the top. After this the water is passed through anion-unit. The anion-unit consist of a strong a strong base unit and weak base unit, and after that it is store in boiler storage tank. The water contain TDS < 50 and pH 8.5-9.

The charging of cation unit is done by using HCL, which is stored in the separate tank, for the charging purpose 10% solution of HCL is prepared. The cation-unit is charched until the Ph is 1.2. After this, washing are done and this water is drain until the pH is around 3-4. Similarly the charging of anion-unit is done by using caustic of strength 10-15%.

The cation load sum of calcium, magnesium and sodium ionic content.

The anionic load is the sum of chlorides, sulphate, nitrate, silica and free carbon-dioxide content of the water from the cation column.

For using the water in the plant the water is further treated by using mixbed tower. It is consist of both cation and anion unit. After passing this unit the water contain TDS < 10 and Ph7. Schematic diagram of DM Plant

Raw Water

BOILER

TECHNICAL SPECIFICATION:TYPE : Three pass smoke tube boiler.MAKE : ThermaxMODEL : S M 60FUEL : Furnace oilCAPASITY : 6 kg/ hr

HCL Tank

Ejector

Cation Tank

Degasser

Caustic Tank

Weak Base

Strong Base

DESING PRESSURE : 17.5 Kg / cm2

PRINCIPLE:A steam generator or boiler is a closed pressure vessel used to generate steam. Its funtion is to transfer the heat produced by the combustion of fuel to water and ultimately to generate steam. It consists of the boiler shell, combustion chamber, grate, furnace, heating surface, moutings and accessories.

Proper mixing of fuel and air is engineered into a mutually supportive combination of burner and combustion chamber to give the highest possible combustion efficiency.

It is necessary that only soft water or demineralized water to be used in the boiler.If hard water without treatment is used, then there is chance of hard scaling in the boiler which may result in the reduce efficiency.

WORKING OF BOILER:In the fire tube boiler the flame or hot gases passes through the tubes, which are surrounded, by water. The heat release in the chamber is absorbed by surround water by conduction and radiation. The gasses from the combustion chamber reverse in water cooled integral reversal chamber into the first set of convection tube. At the end of second pass gasses again reverse in front of refractory door into the second set of convection tubes.

BOILER MOUNTINGS:

1.Water level indicator2.Pressure gauge3.Steam stop valve4.Safety valve5.Blow down valve6.Air ventilator7.Mobery valve8.Air blower

BOILER ACCESSARIES:

1.Oil preheater2.Oil filter3.Feed pump

Safety valve Chimney Feed pump

Main steam Stop Valve

BOILER

Treated water

Oil tank

BURNER

Oil Filter

Blower

Blow Down valveAir inlet

NITROGEN PLANT

1) PLANT SPECIFICATION

AIR COMPRESSOR:

MAKE : K.G KHOSLADISCHARGE PRESSURE : 7.5 KG/CM2TYPE : VYDT

PRESSURE SWITCH

TYPE : IPSSERVICE : OIL RANGE : 0-9 KG/CM2DIFFERENTIAL : FIXEDLOCATION : AIR COMP.MAKE : INDFOS

AIR DRYER CAM TIMER

TOTAL CYCLE PERIOD : 10 MINTYPE : CT 104CAMS : 3VOLTAGE : 230S.R : C17500

PRESSURE REGULATOR

RANGE : 0-10.6 KG/CM2MAKE : SHAVO NORGEN

RTD (RESITANCE TEMPARTURE DECTECTER)

TYPE :PT 100S.NO :502147O.D :6MMS,L :300MM MAKE :RADIX

ROTA METER

S.NO :95-961/R.281MODEL NO :CIVF/PG-8MAKE : EUREKA

SOLONOID OPERATED ON-OFF VALVE

TYPE :51400-6-2GW.N :11224/3ATM :2-10MAKE : ROTEXLINE SIZE :25MM

WORKING OF NITROGEN PLANT

Working Principle:

Filtered air is sucked in to the system which is then passed through the intercooler in which water is used to cool the air up to ambient temp. The temp of water is 32ºc. This is a shell and tube type of heat exchanger where water is in tube. Compressed air then passes through the after cooler. Then it goes to the wet air receiver. Drainpipe is used to drain moisture from the bottom. After that air is passed through the pre filter and fine filter in order to remove the moisture. The air from filter is passed through a thin absorbing tower (known as CMS tower) at the bottom. At the bottom of the towers a alumnae layer is provided to absorb the moisture from compressed air. After a layer of activated alumnae, carbon molecular sieves are provided which absorb oxygen, CO2 & moisture. At a time one absorber remains in cycle while the other undergoes regeneration. The alternate CMS tower keeps switching automatically every one min.

Double Acting Air Compressor

Intercooler Compressor

After CoolerReceiver Tank

Candle Filter Carbon Filter

Air DryerCMS Tower

Surgical tank Nitrogen pure gas receiver

To Plant

by a programmer. Gaseous Nitrogen with better then 99.8% purity is continuously produced. It goes to the N2 pressure-holing vessel. Finally N2 goes to storage tank through flow meter. A pneumatic valve is provided for controlling the impurities.

FFLUENT TREATMENY PLANT

ETP is meant for treating the waste water from Industrial and domestic waste to bring down its chemical oxygen demand (COD) and biological oxygen demand (BOD). This reduction in COD and BOD is brought about by aerobic biological degradation of organic waste water constituents. In our ETP specialized biofixed cultures are used to develop and maintain the biomass in the aeration tank. The specialty of this cultures is they are resistance to fluctuation in the organic load, Ph, toxic chemical etc, their by ensuring stable and trouble free operation. The detailed description of the effluent treatment facility is as follows.

EFFLUENT TRETMENT PROCESS:

1. COMMON COLLECTION SUMP:

Waste water coming from plants, utilities, canteen, and laboratory is collected in the common collection sump where air grid is provided in the bottom of the tank for proper mixing. In this tank on line Ph meter is installed which is coupled with the caustic dosing pump. If pH in this tank is less than 6.0 then caustic dosing pump automatically discharge the caustic slurry and when pH reaches to 8.0, pump will be off. This tank is also equipped with level switch so that raw effluent transfer pump will automatically start and stop according to the level of waste water into the sump.

2. OIL AND GREASE TRAP:

Waste water is pumped from common collection sump to oil and grease trap through a holding tank by using raw effluent transfer pump. In oil and grease appropriate retention time is provided for separation of oil and grease and floating material are collected manually and stored for separation and disposal.

3. EQUALISATION CUM NEUTRALIZATION TANK:

After removal of oil and grease, the waste water is taken into equalization cum neutralization tank where retention time of 24 hours is provided. At this point the pH of the waste water is adjusted between 8.0 to 8.5 by using lime slurry or acid solution, a separated tank is provided for the preparation of the lime slurry and acid solution.

4. FLASH MIXER:

Equalized effluent is pump to the flash mixer where alum and polyelectrolyte is added for the coagulation and flocculation of suspended solids. Here flow meter is installed in the discharge line of the equalized transfer pump which shows the flow rate of equalized effluent is m3/hr. A separated tank is provided for the preparation alum and polyelectrolyte solution.

5. CLARIFLOCULATOR:

From flash mixer waste water comes to clarifloculator under gravity where flocculated solids settled in the bottom of the tank and allow to the clarifier water to flow into the aeration tank. This settled primary sludge should be intermittently (about 4 to 5 times in a shift) removed which will go to sludge thickner.

6. AERATION TANK:

Aeration tank is the first unit in the biological treatment facility. In the aeration tank air is supplied from bottom by using air blower (i.e. diffused aeration system ). The dissolved oxygen level should be maintain between 2.0 to 2.5 mg/I using dissolved oxygen monitoring probe in the aeration tank. Whenever necessary excess siudge should be wasted which will go to sludge thickner.

7. SECONDARY CLARIFIER:Allow mixed liquor in the aeration tank to flow by gravity into the secondary clarifier. Allow the activated sludge to the settle down and recycle back to the aeration tank by using sludge recycle pump. When ever necessary excess sludge should be wasted which will go to sludge thickneer.

8. SLUDGE THICKNER: Primary sludge and secondary sludge are wasted into sludge thickener which reduces the volume of the sludge by compacting it. Settle thicken sludge will be removed to sludge drying bed with the help of slurry pump. Clear water will over flow sludge thickener and goes to equalization tank.

9. BIOFILTER AND MOVING BED FILTER:Allow partial treated effluent to flow from secondary clarifier to treated effluent sump. Pumped this water to biofilter where specilised bacterial cultures is filled. Allow to pass treated water to moving bed filter where sand is kept and keep this sand in fluidized condition by providing pressurized air by using compressor. And use this treated effluent as irrigation purpose.

Process flow diagram of ETP

Effluent from plant Collection Tank-1

Sludge Drying Bed

Oil and Grease trap

Sludge ThickenerOverflow

SludgeAlum TankAcid Tank Caustic Tank

Polyelectrolyte TankClariflocculatorFlash MixerEqualization Tank

Collection Tank-2

CompostingAeration TankSecondary ClarifierTreated Water TankBio FilterMoving Bed filter

Treated effluent disposal

Acknowledgement

I would like to express my deepest gratitude to those individuals without the help & guidance of whom the successful completion of my training programme would not have been possible.

I am grateful to Mr. M. M. Verma, Associate Vice President of Wockhardt Ltd. for allowing me to undertake my training programme in this reputed organization & providing me all the training facilities.

My special regards to Mr. Harsh Kumar, Sr. Production Manager of Wockhardt Ltd. for providing me the opportunity to learn better in his

Department & also providing me a golden opportunity to take active participation in commissioning of a Baby Food Plant at Jaraon, near Ludhiana.

I am also very much thankful to Mr. R. K. Aggarwal (Sr. Quality Manager), Mr. R. K. Anand (Sr. Engineering Manager), Mr. S. Mehta (Asst. Manager of Store), of Wockhardt Ltd. for allowing me to undertake my training in their respective department.

I am also grateful to Prof. A. K. Misra, Dean of the Faculty Dairy Technology, West Bengal University of Animal & Fishery Sciences for giving the chance to carry out my valuable In-Plant training at Wockhardt Ltd.

I wish to express my thanks to Mr. Saibal Saha, my training mate, who help me to a great extent in carrying out my training.

Last but not least I feel privileged in conveying my thanks to my family members for their invaluable support. I am indebted to them for their noble gesture.

Dated:Place: Pradip Mondal

INDEX

Serial No.

Subjects

1 An introduction to Wockhardt group

2 Raw & finished Goods store

3 Milk Procurement

4 Quality Assurance Department

5 Engineering Department

AN

INTRODUCTION

TO

WOCKHARDT GROUP

Introduction

Wockhardt’s Nutritious food processing plant is located at Lalru, Punjab at distance of 37 km from Chandigarh on NH 22 at village Sarsini in district of SAS nagar, Mohali.

Wockhardt is a leading a pharmaceutical company & 2nd largest Baby food manufacturing company in India & is committed towards the excellent quality product & services through innovative technology. It is rapidly diversifying to be complete health care company. This group is constantly growing with turnover of near about 125 crores.

The Plant at Larlu has set up with the latest technology available in the industry to manufacture a range infant formula, health drips & cereal foods from the fresh milk.

This state- of -the art technology involves an investments of 42 crores. It has a capacity to produce over 4000 tones of spray dried powder.

The process & packaging machinery installed in the industry have been imported from U. K, Germany, Holland, Belgium. Other process like triple effect evaporator, spray drier etc. are being installed by SSP Pvt. Ltd.

At Wockhardt, the major attention is given to the quality production rather than the quantity production. Every possible care is taken to ensure the cleanliness & hygiene of the plant. Good manufacturing practices are followed here.

Details of Products manufactured in Wockhardt ltd.

Protinex: It is renowned brand name owned by Wockhardt Ltd. it is the ideal protein

supplement & is scientifically formulated. Protinex with a high protein content, supplies essential amino acid & is fortified with essential vitamins & minerals. This makes Protinex a wholesome nutritional drink for adults.

Farex:Farex infant formula is a spray dried formula for healthy Infants. Farex Infant

formula contains vitamins & minerals known to be essential for the development of the infants. Major ingredients are edible vegetable oil, demineralized whey & whey solids, soya lecithin, partially skim milk, minerals & vitamine.

Farex growth plan is designed to provide infants with coplete nutrition & healthy eating experiences. As their infants progress from stage 1 to 3, Farex growth plan meets their changing needs, from smooth consistent food to variety for developing taste buds & textures for teething. Major ingredients are wheat flour, milk solids. Sucrose, edible vegetable oil.

Dexolac: It is infant milk substitute. It can be given to the babies’ upto the age of six

months. Major ingredients of dexolac are partially skim milk, maltodextrin, edible vegetable oil, sucrose, minerals & vitamine.

Dexolac SC:It is also infant milk substitute. It is a special care product for low birth weight

children. The ratio of whey to casein is 60:40. Major ingredients of dexolacSC are partially skim milk, maltodextrin, edible vegetable oil, whey protein concentrate, sucrose, minerals & vitamine.

Nusobee:It is a lactose free & sucrose free infant milk formula. Nusobee is specially

designed to maintain infants suffering from lactose intolerance & common problems associated with it. Major ingredients are edible vegetable oil, soya protein isolated, soya lecithin, minerals & vitamine.

Nusobee Casein:It is a lactose free infant milk formula. In comparison to Nusobee, Nusobee

Casein is only lactose free but not sucrose free. It is a lactose free & sucrose free infant milk formula. Nusobee is specially designed to maintain infants suffering from lactose intolerance & common problems associated with it. Major ingredients are edible vegetable oil, soya protein isolated, soya lecithin, minerals & vitamine.

Recupex:It is nutrinally balanced complete diet. It is specially prescribed in following

conditions:- Convalescence, mal nutrition, in cancer patients, fever associated with typhoid, malaria & respiratory tract infection, post surgery, coma, neurological disorder etc.

Nutriprot:It is a nutritional supplement for high protein caloric needs. Major ingredients

are edible vegetable oil, whey protein concentrate, soya lecithin, liquid glucose, glutanine, minerals & vitamine.

Nutrenal:It is a low protein low salt for chronic renal failure patients. Major ingredients

are edible vegetable oil, maltodexrin, soya lecithin, liquid glucose, casein, minerals & vitamine.

Nutrocal:It is scientifically designed balanced eternal nutrition. The flavour being

manufactured is vanilla. Major ingredients are edible vegetable oil, maltodexrin, soya lecithin, sucrose, hydrolyzed casein, whey protein concentrate, minerals & vitamine.

Nutrocal DM:It is a scientifically designed complete nutrition for diabetics. Major ingredients

are edible vegetable oil, maltodexrin, soya fibre, gum acacia, migrocrystalline cellose, sucrose, whey protein concentrate, minerals & vitamine.

Dexrice: It is a delicious weaning food. It is the major cereal based food. It should be

introduced after 4 months of age in addition to mothers’ milk. Apart from others ingredients extruded rice flour is also added.

Firs Food:It is a weaning food. Instead of extruded rice flour added in dexrice, extruded

wheat flour or extruded apple is added

QUALITY ASSURANCE DEPARTMENT

I. Chemical and microbiological examination:

The milk received in dock undergoes various platform testes before it is being accepted or rejected. The factory has certain definite standard parameter on the basis of which acceptance or rejection is being made. If the milk standards are upto the mark, then it is chilled and stores in different silos. The various test undergone are:

1) Chemical test:

a) Organoleptic test “( Colour, Smell, Flavour, Apprence and Taste )b) Fat testc) CLR or SNF testd) Alcohol teste) COB TEST

2) Preservative:

a) Formalineb) Hydrogen peroxidec) Boric acidd) Rosalic acid test

3) Neutralizer:

Acidity difference ( Difference of .03% in acidity before and after boiling confirms the test.)

4) Adulterants:

Sugar , common salt, Glucose, Starch, Maltodextrin and Chemicals.

II. Chemical lab:

In the chemical lab, various packed products, raw materials, packing materials, packaging materials, in process products are tested for their quality. Packed products of each batch are received by the lab in the, out of which the two are stored as control samples so that in case of any future complain they may accordingly referred. This packed material is tasted for different nutrients such as Fe, ca, k, mg etc. The protein content also determined using kjeldel method. Gravimetric moisture and ash content is also determined of the pack sample. Any product should not have high moisture content, otherwise it may get spoiled.

Raw material and packing material are also tested in the chemical lab. The major raw materials include.Maltodextrien, Refine sugar, whey protein concentrate, crystalline sugar, vegetable oil etcStandardize procedure are followed for testing of raw and packing materials which are enlisted in standard operating procedure. Any raw and packing material can not be used without the clearance from the laboratory. The major packing materials are

TinLaminated foilShipper (corrugated fiber board box)CartonsWater testing is also performed in the laboratory. Different water sample are being are tested for ph, total hardness, chlorine content etc.

III) Instrument lab:

The laboratory is equipped very sophisticated instruments being used for the analytical analysis. With the help of this instrument the result are obtained with great precision and perfection and less time also. All the instruments are calibrated for the different products.The major instruments in the laboratory are:

Métier ph meterHACH meter for estimation of the Na contentWTW apparatus for determining conductivitySeam analyzerFlame photometerCalorimeterHACH DR-400 spectophotometerLeak test apparatusTensile strength meterMettle balance

IV) Microbiological examination:

All the raw materials as well as the packed materials are being tested for the SPC and coliform counts. The raw material as well as finish material cannot be utilized or packed without the microbiological clearance. The permitted SPC counts of different materials are being enlisted and any product found to have count more than the permitted one is being rejected by the microbiologist. The water samples are also being tested for the SPC and coliform counts. Also the line testing from raw milk to the final powder is done to check and detect the source of contamination during the manufacturing of powder.

V) Sampling:

The samples are taken every half an hour. The testing of this running sample is done so as to detect any change from the prescribe parameters at the root level only and can be accordingly corrected. The different test performed on each samples are :

Organoleptic testMoistureBulk densitySolubility indexScorched particleFat %Co lour

Composite sample:

All the half hourly samples are mixed at the end of the day to make a composite sample for testing as the second testing removes any unwanted errors and the second testing confirms the test report of the first sample test.

Sensory evaluation:

The test panel, comprising of all managers, does sensory evaluation of the product. The testing is done for various parameters and judge according to the “ 9 point score programmed.” The quality assurance department then analyzes these score and the consumer acceptability is predicted.

The different type of tests carried on these samples are: Physical test:

1. Moisture2. Bulk density3. Solubility index 4. Scorched particle5. Colour

Chemical test:

1. Fat2. Protein3. Ash4. Acidity5. Crude fiber6. Vitamin and Minerals

Microbiological test:

1. SPC2. Coliform and E.Coli3. Staphylococcus aures and Salmonela for monitoring pathogens.

VI. Records for analyzing report:

The following records are being maintained by quality assurance department :

1. Milk reception records :

Milk weighingDock testingIn-process milk testingStandardization sheet

2. Raw material record :

Raw material inspection recordRecord of rejection

3.Powder manufacturing:

Routine powder testing record Composite sample record BIS record

3. Powder packing record :

Batch control record Line inspection record Powder rejection record

4. Packing material record :

Packing material testing record Rejection report

5. Hygiene and environment control :

Water testing Line testing Pest control record

VII. Handling of complains

For handling the consumer complains and having a check on the powder quality, samples are taken from the each batch and are stored. These samples are opened periodically tested after 4 months, 8 months, and 12 months time to determine the batch quality chemically and microbiologically. In case of complaints, these samples may be opned to test the validity of the complaints.

VII. In process quality control:

The control of the quality assurance starts from the moment the milk is received at the dock. The milk received is tested for fat, snf, temperature, neutralizer, preservative and adulterants. It is then chilled to 4-6 C and then pumps into silos for storage.

The silos are also tested for temperature and composite fat and SNF of the milk before and during the standardization.

Final fat and SNF ratio is then tested with other parameters like acidity, temperature etc, before the milk goes in for concentration.

The concentrate from the evaporators is also tested for the TS content acidity etc.

Testing of the powder after every half an hour for bulk density, moisture, burnt perticle and solubility index is done to ascertain the quality of the powder being manufactured.

Every day online testing of the packed material is also done to keep a check on the performance of the packing machinery. The tin packs and pouches are randomly checked for the oxygen content to the ascertain if the nitrogen filling is properly being done or not.

Also, the cream separated during standardization is also tested for its temperature, fat, acidity and finally ghee is tested according to the Agmark norms.

Flow diagram IN PROCESS QUALITY CONTROL

Raw milk receptionTesting for fat, SNF, preservative, adulterants and

temperature.

Chilling of raw milk

Pasteurization temperature check

Silo testing (fat, SNF etc)

Check standardization silo

Check final fat, SNF ratio

Concentrate testing

Half hourly testing of powder

Composite sampletesting

Packing materialtesting

Packed materialtesting

Raw

&

Finished Goods

Store

STORES

It is the most important department of Wockhardt Ltd. As well as any other organization, we can say that it is the backbone of any organization. In one ward we can say that plant starts with store and finishes in store. All the activities in the Wockhardt Ltd. are controlled by the fully automatic SAP system, which is online process and also connected to Head offices as well as all other plants in the world. Store has approx. 200 raw and packing material and approx 29 types of finished products.

Manpower in store:

ASSTT MANAGER STORES : 01STORE ASST : 01STORE OPERATOR : 01STORE HELPER :0 2

Department in store:

There are three segments in store1. Raw material segment2. Packaging material segment3. Finish good segment

Purchase planning in Wockhardt

Raw material and packing materials are purchased from Head office through SAP. When any department needs to purchase materials, it is purchased as follows

1. Firstly Material Requisition is made by the concern department.2. Then the Quotation is taken from suppliers’.3. The Purchase order is made by compiling the quotation.4. Then it is send to proper & suitable suppliers’.5. After that the materials are delivered to the mention places with in mention

time.

Terms and condition of purchase

1. The acceptance of this order shall be communicated in writing on receipt hereof in absence of a written acceptance hereof the delivery of any materials.

2. Invoice shall be rendered to buyer one week from the date of delivery goods.

3. All statement of accounts shall be rendered on or before such time as may specified in the order.

4. Material are subjected to buyers inspection and approval at destination and if rejected if rejected on intimation thereof to seller and in the absence of any instruction from the seller for disposal of rejected supplies a period of two weeks from the date of the afore said intimation.

5. The sellers agree to assume and pay all extra expenses or any loss on accounting of improper packing.

6. Any transportation charges to which seller is should be added to sellers in voice.

7. The buyer may at any time by written order make changes in the drawing desing of specification applicable to the supplies convert by this purchase order.

8. The seller shall deliver the supplies to buyer at the buyer’s places of business.

9. The buyer assume on obligation in the relation to the supplies delivered in excess of more specially ordered

The buyer will not be liable in respect of any order not given or confirmed on its official printed forms dully singed by the buyer or its authorized representative.

Goods Receipt:

1. When the goods come onto the plant, the security at the gate checks the gate entry and gives a stamp on the paper.

2. Then the storekeeper checks the duly singed and stamped gate pass entry.3. Then the store assistant verifies all the documents.4. Store assistant physically checks the material & check the weight and the

quantity of the material is correct or not.5. The Store executive makes GOODS RECEPT into the SAP. This known as

GR.6. Then they paste ON TEST label on the each batch of the material receipt. It

indicates item code, item name, batch no, quantity, unit of measure, total quantity, supplier name and code.

7. After that the quality control department takes sample of each batch and paste SAMPLED label on the material.

8. After that on approval of QAD, they affix APPROVED green label on the each batch of the material received. In case of QAD rejects the material, they affix the REJECTED label.

Check list during unloading of the material:

1. Check the proper gate entry, stamp on the paper.2. Damage and leakage condition of the material.3. Hygienic condition of the truck in which the materials are received.4. The presence of the vival and insects in the material.5. Ensure that the air curtain is in operation or not during unloading.6. Close the shutter and outer door of the clean up area at the unloading.

Issuing of Raw and Packing material for Production and Packing :

1. Production department order the raw and packing material to store as per their requirement.

2. Then the approved materials are transferred to the Production department as per their demand according to Bill of Material (BOM).

3. After that the production and packing department send the PICK LIST and PACK GOOD TRANSFFER NOTE with finish packed goods.

4. After that the Raw and Packing material are reduce automatically from the SAP when the store assistant entered the PICK LIST and PGTN into the SAP.

5. QAD takes the sample of the finish goods.6. On approval of the QAD the products are ready for distribution.

Distribution of the finish goods:

The product is distributed to the consumer through proper distribution channel. It controls the whole distribution. It is distributed as follows:

1. Sales department study the market as per their requirement & they inform to the Head office.

2. Distribution channel makes Stock Transfer Order (STO) in the SAP3. Store dispatch according to STO.4. When the store assistant enters the STO into the SAP and stock is

automatically balance from the SAP.

Name of the units of single stage Drying Plant

1. Air filter.2. Dumper3. Supply fan4. Air heater5. Hot air inlet6. Nozzle holder 7. Spray Nozzle8. Drying Chamber9. Services Door10.Main Cyclone11.Exhaust fan12.Exhaust fan dumper13.Receiver14.Rotary valve15.Blow Through Valve16.Radiator17.Conveying Cyclone18.Shifter19.Powder to Bagging Room20.Lumps out21.Conveyer fan22.High pressure fan23.Plate heat exchanger24.Homogenizer25.Feed pump26.Duplex filter27.Concentrate tank28.Dehumidifier29.Steam in 30.Steam out31.Chilled in32.Chilled out

IN-PLANT TRAINING REPORTOF

WOCKHARDT LTD., LALRU, PUNJAB

A REPORT SUMITTED TO THEWOCKHARDT LTD. FOR

THE AWARD OF THE DEGREE OF BACHELOR OF TECHNOLOGY

INDAIRY TENHNOLOGY

BYMR. PRADIP MONDAL

FACULTY OF DAIRY TECHNOLOGY

WEST BENGAL UNIVERSITY OF ANIMAL & FISHERY SCIENCES

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