Detailed Project Report on milk processing unit

MILK PROCESSING UNIT

[CODE NO.3876]  

The importance of milk in human diet especially for children and expectant and nursing matters is vital.  

Unlike rich countries like the U.K. and the U.S. dairying in India is a subsidiary occupation of almost all the farmers. More than 60 per cent of the families involved in dairying belong to the small or marginal farmers or even agricultural labourers.

In the first half of the 1900 dairying in the country was largely unorganized, except for military farm which were established and largely stocked with the European breeds. In the plantation areas, pure breed exotic bulls were randomly crossbled with local cows. Apart from the "poskets" of improved animals thus created, dairying was largely left in the hands of traditional producers, middle man, product makers and vendors.

Some private dairies were more or less modern processing facilities were encouraged to make pasteurized butter mainly for the British Army. In the early 1940's one such firm also become the prime supplies to the country's first official urban milk supply scheme "The Bombay Milk Scheme". Under it chilled milk was transported in cans by rails to Bombay from Anand in Kheda District some 425 km from Bombay.

When India became independent in 1947, are of earliest projects of its type to be adopted was the creater Bombay Milk Scheme which consisted of a market milk plant in Bombay, supplied with milk by the Khairs District Cooperative Milk producers union.

The union which had its processing plant close to the town of Anand, ultimately came to be known as the Anand Milk Union Ltd abbreviated to Amul, meaning "beyond price" or priceless".

The world’s largest during development programme the operation flood is distinguished by its involvement of small holders and landless rural milk producers. It aims to create a "flood" of usually-produced Milk assuring the farmer of remunerative price and ready market and the urban consumer of wholesome milk at stable and reasonable prices.

The modern dairy sector was best with problems, the more important of which were as follows.

State Government found it difficult to effectively against milk production, procurement processing and marketing.

The urban dairies were unable to obtain more than a 30 per cent share of their liquid-milk markets.

"Dairy development" had after been treated as if-it were synonymous with building dairy processing plants and there plants frequently got built in the towns where the consumers were, rather than in the milk-sheds where milk was produced and so they had found if difficult to organize rural milk procurement.

To provide the safest and highest quality product to the consumer, the Pasteurized Milk Ordinance (PMO, 2005) provides standardized guidelines. The PMO is a document from the United States Departments of Health and Human Services and Public Health, and the Food and Drug Administration that defines practices relating to milk parlor and processing plant design, milking practices, milk handling, sanitation, and standards for the pasteurization of Grade A milk products. Each state regulates their own dairy industry, but the state's guidelines usually meet or exceed those defined by the PMO. Milk that is shipped between states must follow the PMO regulations.

Milk is obtained from the cow (or goat, sheep, or water buffalo) under sanitary conditions and cooled to 45°F (7°C) within 2 hours of milking. Milk is picked up by a handler who takes a sample and then pumps the milk from farm's bulk tank into the milk truck. A handler may pick up milk from more than one farm, so a truck load may contain milk from several farms when it is delivered to the processing plant. Before the milk can be unloaded at the processing plant, each load is tested for antibiotic residues. If the milk shows no evidence of antibiotics, it is pumped into the plant's holding tanks for further processing. If the milk does not pass antibiotic testing, the entire truck load of milk is discarded and the farm samples are tested to find the source of the antibiotic residues. Regulatory action is taken against the farm with the positive antibiotic test. Positive antibiotic tests are rare, and account for far less than 1% of the tank loads of milk delivered to processing plants.

Milk at the plant is stored at less than 45°F (7°C) and is usually processed within 24 hours, but can held for up to 72 hours (3 days) before processing. Longer holding time allows for growth of spoilage organisms that grow at refrigerator temperatures, called psychrotrophs.

COST ESTIMATION

Plant Capacity                             10,000 Ltr./Day

Land & Building (1500 sq.mt.)     Rs. 2.09 Cr

Plant & Machinery                        Rs. 80 Lac

Working Capital for 2 Months    Rs. 3.06 Cr

Total Capital Investment             Rs. 6.18 Cr

Rate of Return                              47%

Break Even Point                         41%

• INTRODUCTION
  
• KINDS OF MILK
• PROPERTIES DETAILED COMPOSITION OF MILK
• FACTORS AFFECTING COMPOSITION OF MILK
• TABLE
• PROPERTIES OF MILK
• TYPES OF MILK
• RAW MATERIALS
• MARKET OVERVIEW OF MILK PROCESSING
• GLOBAL MARKET SCENARIO OF MILK
• PROJECTION HIGHLIGHTS
• PER CAPITA CONSUMPTION OF PROCESSED AND FRESH DAIRY 
•     PRODUCTS IN MILK SOLIDS
• PRICES
• DAIRY PRODUCT PRICES
• PRODUCTION
• ANNUAL CHANGES IN INVENTORIES OF DAIRY HERD AND YIELDS 
•     BETWEEN 2019 AND 2028
• MILK PRODUCTION AND YIELD IN SELECTED COUNTRIES AND REGIONS
• CONSUMPTION
• TRADE
• EXPORTS OF DAIRY PRODUCTS BY REGION
• IMPORTS OF DAIRY PRODUCTS BY REGION
• MAIN ISSUES AND UNCERTAINTIES
• MANUFACTURING PROCESS
• COOLING AND STORING MILK:
• FILTERATION:
• STANDARDISATION:
• HOMOGENISATION:
• CLARIFICATION:
• PASTEURISATION
• PASTERIZATION REQUIREMENTS:-
• THE FOLLOWING ARE THE MAIN SYSTEM OF PASTEURIZATION.
• STING
• PACKING
• FLOW DIAGRAM
• DETAILS OF MILK PROCESSING
• 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
• TABLE. PASTEURIZATION CONDITIONS USED FOR MILK PRODUCTS.
• TECHNICALITIES IN MILK PROCESSING UNIT
• SOME SIGNIFICANT BENEFITS OF MILK PROCESSING PLANTS:
• STEPS TO SET UP MILK PROCESSING PLANTS
• STEPS TO SET UP MILK PROCESSING
• GUIDE TO START AND RUN MILK PROCESSING PLANT
• MILK QUALITY AND TESTING
• PASTEURIZATION
• COOLING
• PACKAGING AND CAPPING
• QUALITY ASSURANCE
• SUPPLIERS OF PLANT & MACHINERY

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)