Milk Processing

MILK PROCESSING

[EIRI/EDPR/4377] J.C.: 2569XL 

INTRODUCTION

The milk of each species seems to be a complete food for its own young for a considerable time after birth. In the stomachs of the young, milk is converted to a soft curd that encloses globules of fat, enabling digestion to proceed smoothly without the disturbance often caused by fatty food. Lactose, or milk sugar, is broken down into simpler digestible sugars by the enzyme lactase, which is produced in the intestine of infants. Infants who do not produce lactase develop lactose intolerance, a condition in which a variety of gastrointestinal problems arise. Lactose intolerance also commonly develops after weaning or with advancing age, when many individuals cease producing lactase.

Milk protein is of high nutritional value because it contains all the essential amino acids—i.e., those which infants cannot synthesize in the necessary quantities. Milk’s mineral content includes calcium and phosphorus in quantities sufficient for normal skeletal development, but little iron. Milk contains B vitamins as well as small amounts of vitamins C and D. Commercial cow’s milk is commonly enriched with vitamins D and A before sale.

Microorganisms contained in raw (unheated) milk or picked up from the environment will quickly sour and curdle the milk. Cooling to slightly above its freezing point keeps milk palatable for a longer time by reducing the multiplication of spoilage bacteria and the chemical changes that they induce.

Many countries have laws requiring that milk be pasteurized as a protection against pathogenic (disease-causing) organisms. Pasteurization is a partial sterilization accomplished by raising the milk to a temperature high enough to destroy pathogenic bacteria and a large proportion of those causing spoilage. Pasteurized milk that is kept refrigerated in closed containers will remain consumable for approximately 14 days.

Milk fat, being less dense than other milk components, can be efficiently removed in a cream separator by centrifugation, yielding low-fat milk and skim milk. Low-fat milk contains 1–2 percent fat, while skim milk contains less than 0.5 percent fat.

Much of the milk sold as a beverage has undergone homogenization, a process in which the milk is forced under high pressure through small openings to distribute the fat evenly throughout the milk.

The dairy market in India reached a value of INR 13,174 Billion in 2021. Looking forward, the publisher expects the market to reach INR 30,840 Billion by 2027, exhibiting a CAGR of 14.98% during 2022-2027.

It is intended to prepare a Feasibility Report to install 200000 LTRS/DAY Milk Processing Facility as a Green Field Project. 

COST ESTIMATION

Plant Capacity                                     2,00,000 Ltr./Day

Land & Building (4420 sq.mt.)  Rs. 4.64 Cr

Plant & Machinery                              Rs. 9.86 Cr

Working Capital for 0.033 Month  Rs. 90.71 Lac

Total Capital Investment                 Rs. 16.00 Cr

Rate of Return                                   76%

Break Even Point                              48%

CONTENTS

INTRODUCTION

PROPERTIES 

BENEFITS

TYPES OF MILK

TONED MILK

DOUBLE TONED MILK

STANDARDISED MILK

FLAVOURED MILK

FULL CREAM MILK

BOILED MILK

MIXED MILK

RECOMBINED MILK

SKIMMED MILK

FACTORS AFFECTING COMPOSITION OF MILK

MARKET OVERVIEW

INDIAN MARKET

STATE-WISE SEGMENT INSIGHTS

VALUE-ADDED PRODUCT WISE SEGMENT INSIGHTS

EXPORT-IMPORT

KEY GROWTH DRIVERS OF THE MARKET:

KEY DETERRENTS TO THE GROWTH OF THE MARKET:

GLOBAL MARKET

RAW MATERIALS

BIS STANDARDS

MILK AND MILK PRODUCTS

MANUFACTURING PROCESS STEPS 

COOLING AND STORING MILK

FILTERATION

STANDARDISATION

HOMOGENISATION

CLARIFICATION

PASTEURIZATION

PASTEURIZATION REQUIREMENTS:-

THE FOLLOWING ARE THE MAIN SYSTEM OF PASTEURIZATION

STING

PACKING

PROCESS FLOW

DETAILS OF MILK PROCESSING

COLLECTING

SEPARATING

FORTIFYING

PASTEURIZING

HOMOGENIZING

PACKAGING

METHODS OF PASTEURIZATION & ITS BENEFITS

VAT PASTEURIZATION

HTST PASTEURIZATION

BENEFITS OF HTST PASTEURIZATION

PASTEURIZATION TEMPERATURE & TIME CHART

PASTEURIZATION CONDITION USED FOR MILK PRODUCTS

TECHNICALITIES - MILK PROCESSING UNIT

SOME SIGNIFICANT BENEFITS OF MILK PROCESSING PLANTS:

STEPS TO SET UP MILK PROCESSING

IF YOU ARE RUNNING MILK PROCESSING PLANTS THEN YOU SHOULD REMEMBER THE FOLLOWING POINTS.

GUIDE TO START & RUN MILK PROCESSING PLANT

IN ADDITION, THERE ARE MANY TECHNIQUES OF MILK PROCESSING THAT DONE BY DAIRY FARMERS. THESE PROCEDURES ARE GIVEN BELOW:

MILK QUALITY AND TESTING

PASTEURIZATION

COOLING

PACKAGING AND CAPPING

QUALITY ASSURANCE

SUPPLIERS OF PLANT & MACHINERY

ENGINEERING DESIGN CONSIDERATIONS

SEWAGE AND WASTE WATER EFFLUENT 

STP FLOW DIAGRAM (TYPICAL)

UTILITIES REQUIREMENT (ESTIMATED-MONTH)

PRELIMINARY LAYOUT

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

ANTICIPATED ENVIRONMENTAL IMPACTS 

CONSTRUCTION PHASE 

OPERATION PHASE 

MITIGATION MEASURES (PROPOSED)

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)