BY-SHIVANI SAXENA (2K10MKT28)GOUTAM DAS (2K10MKT35)

PROJECT REPORT ON INDUTRIAL VISIT TO MOTHER DAIRY

Submitted to-Prof.

Mother Dairy was set up in 1974 under the operation flood programme .It is now a wholly owned company of the NATIONAL DAIRY DEVELOPMENT BOARD(NDDB),whose current chairman is Dr. Amrita Patel. Currently, it is one of the largest milk ( liquid/unprocessed) plants in Asia selling more then 25 lakh litres of milk per day, thereby enjoying a market share of 66% of the branded milk sales in Delhi & NCR and undertakes its marketing operations through 14000 retail outlets and 845 exclusive outlets.

It is Mother Dairy’s constant endeavour to:A) Ensure that milk producer and farmers regularly and continuosly receive market prices

by offering quality milk,milk products and other food products to consumers at competitive prices.To ensure that Mother Dairy operates such that the farmer gets 85% of the total cost of sales.

B) Uphold institutional structures that empower milk producers and farmers through processe that are equitable.

Structure of the company!!!CHAIRMAN

MANAGING DIRECTOR

DEPARTMENTAL HEADS

CHIEF EXECUTIVE OFFICER

GENERAL MANAGER

DEPUTY GENERAL MANAGER

SENIOR MANAGER

MANAGER

DEPUTY MANAGER

STAFF

With the Deputy General Manger of Mother Dairy(Patparganj,New Delhi)

Mr.Kar.

LOCATION OF THE PLANT

PLANT LAYOUT AND PROCESS!!!Regional milk

procurement centresMilk procurement and

testing lab.

Refrigerated storage silos

Clarification unitStandardisation UnitHomogenisation Unit

Pasteurisation Unit Milk fortification unit

Refrigerated storage silos

Packing unit

Ice cream manufacturing unit

Dairy products manufacturing

Sent to various distribution Networks

The various departments in Mother DairyPatarganj Milk plant : Manufacturing Department Production Department MIS Department Utility Department Safety,Health & Environment Department Thermal Department Electrical Department Automation Department Procurement Department Consumer Information Department.

SUPPLY CHAIN MANAGEMENTMILK PROCUREMENT-Mother Diary sources its requirement of liquidmilk from dairy co-operatives and producerinstitutions. Milk is received from farmer cooperatives through insulate road/rail tankers atvery low temperature in order to retain itsfreshness.

MILK DISTRIBUTION PROCESS79 tankers in the morning and 75 tankers in the evening bring milk from the regionalcollection centers' . After collection the same tankers are utilized for the delivery of theprocessed milk to the vendors and outlets . Mother Dairy has over 820 milk distributionoutlets in the National Capital Region . Each of these outlets place their demand byraising an invoice one day in advance . The demand is also calculated using the‘Calendar’ scheme ,in this depending on the pre-calculated seasonal demands theoutlets place their orders accordingly. In order to satisfy immediate demand, 20 to 25tankers are provided with a buffer stock of 500 liters' each day so that they canmobilized to cater the demand in an area .To coordinate its operations all tankers areequipped with HAM radios.

Distribution ChannelsA) Token distribution:Also termed as “Lohe ki bhains” ( metalbuffalo),is an automated milk vending machine.

B) COW:Container on wheels or Cow is a manual milkdistribution program in whick cycle-rickshawsare employed for milk distribution.

C)Retailers:The packaged milk is distributed via the retailer networkthroughout the city.

QUALITY MANAGEMENTStringent quality control methodologies are Employed in Mother Dairy.a) The milk is tested for adulterations and quality at the time of collection.b) The milk that comes from the collection points to the Mother Dairy plant is

ensured to have a temperature of not more than 7*C and is subjected to 15 product and quality checks.

c) The milk quality is checked repeatedly after each processing phase and the temperature is judiciously maintained less than 5’C always.

d) Before the milk leaves plant for delivery/distribution outlets the milk is tested again.

e) The temperature of milk in the delivery trucks is always maintained less than 7’C.f) All the trucks that deliver milk have specified guidelines to bring back 100 litres of

milk after distribution.This is done in order to test the delivered milk and to ensure that the tankers are not adulterated during distribution.

g) Since all the employed processing techniques are automated , no contamination by human hands take place.

h) To ensure milk freshness the collection and distribution points are always chosen such that the travel time between them is always chosen such that the travel time between them is always less than 36 hours.

PROCESSING ANALYSISAt Mother Dairy , processing of milk is done through state-of-the-artMicroprocesser technology which integrates and completelyautomates all functions of milk processing and ensures high productquality , reliability and safety.The various stages of milk processing are-

1) CLARIFICATION2) STANDARDISATION3) HOMOGENIZATION4) PASTEURIZATION

Clarification:The chilled milk from the silos goes to theClarifier after pre-heating.The clarifier spins the milk at veryhigh speed,removing all dust particles that are visible to thenaked eye.

Standardisation:Milk from different breeds of cows and buffaloes varies in itscomposition.Hence,to make milk uniform in composition,it isstandardised by raising or lowering its fat and SNF percentage to adesired level,so as to deliver the milk to consumers as perprescribed PFA norms.

Homogenisation:In this process, the milk is subjected to a very high pressure due to which the large fat globules present in

milkare broken down into tiny droplets.The milk fat gets evenly distributed and milk appears whiter andthicker.Milk is homogenised for consumers who do not like creamy layer on top.Homogenisation improvespalatability of milk.

Pasteurisation:In this process, the milk is heated at 72’C fot 15 seconds and then is rapidly cooled down to the 4’C.This process kills all the pathogenic bacteria present in the milk making milk safe for consumption.Pasteurisation,unlike boiling does not afect the nutritive value of milk.Pasteurisation,named after French scientist Louis Pasteur who invented the process was first applied to milk by Dr.Soxhlet of Germany .

MAINTENANCE MANAGEMENT• Maintenance is analysed and tracked on a monthly basis.

• Mother Dairy plant and booth are washed and cleaned daily following the under-mentioned procedure-

1) Washed with warm water2) Washed with warm water + Sodium hydroxide.3) Washed with warm water again.4) Washed with warm water and chlorine.

This procedure is maintained in all mother dairy booths every45 minutes and at the plant in every seven hours.

INVENTORY MANAGEMENT

Mother Dairy use TPM i.e Total ProductivityManagement as per which,there is-Zero AccidentsZero Break downsZero Cost wasteZero Defects

Safety & Quality standards• Mother Dairy is an ISO 9002 IS 15000 HACCP and EMS

certified organisation.• Mother Dairy has been awarded ISO 9001:2000(Quality

Mangaement systems) , HACCP, 2002(Food Safety Management Systems) and ISO 14001:2004( Environmental Management Systems certifications.

• Moreover,National Accredition board accredits its quality Asuurance Laboratory as per ISO/IEC 17025:1999 for Testing and calibration laboratories,Department of science and technology,Government of India.

THANK YOU