MAHANAND Dairy Industry

PREFACE

Summer Internship Programme is a part of MMS Programme, which is very helpful in getting practical knowledge in this globalization world. Now-a-days only theoretical knowledge is not enough to success in life but most important we must have practical knowledge. With the help of this training, I came to know how to apply theoretical knowledge in practice.

Main purpose of this training is to have awareness about industrial environment and to know about different functions of an organization like Distribution, Production and Marketing.

         I got an opportunity in MAHANAND DAIRY, Goregaon to undergo Summer Internship Programme as a part of MMS Programme. I consider myself privileged that I got a chance to work with reputed company and can upgrade my knowledge related to practical aspect of business world which is very helpful in my career building. 

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STUDENT DECLARATION

                        I hereby declare that this dissertation submitted in partial requirement for award of MMS Systems to Mumbai Institute of Management & Research is my origin of work and has not been submitted for award of any other degree or diploma fellowship or for similar titles.

      The information presented through this project is true & original to the best of my knowledge.

 

INDEX

SR NO.	TOPICS
1.	Welcome to Mahanand Dairy
2.	Apex Federation of District / Taluka
3.	Contact
4.	Organization chart
5.	Why process milk?
6.	What problems can arise?
7.	Processing techniques
8	ERP definition
9	Process Automation and Integration
10	Software Development
11	SWOT Analysis

Welcome to Mahanand Dairy  

MAHANAND DAIRY.

Mahanand Milk , the World-Wide Taste of Happiness.Mahanand Dairy is the Largest Cow Milk packing and distributing dairy in Asia. Mahanand Dairy is always related to any breakthrough or advent in the Milk Production and Dairy Technology in India. Mahananda has launched Mahanand Parijatak Scheme.

Milk is that inevitable bond which binds a child to its mother, a bond to which everyone can relate. Mahanand Milk keeps alive the Indian heritage, helping strengthen and nurture the bond.

At present Mahanand Dairy is distributing 8.5 Lac Litres milk per day through 722 milk distributors (Ex Dairy Distributors -174 and shop Distributors, Commission Ag ents etc. - 548).

MRSDMM is an Apex Federation of District / Taluka milk unions established to implement the Operation Flood programme in the state of Maharashtra.

The main objectives of MRSDMM is to procure milk from the member milk unions at remunerative rates and distribute the same to the consumers at reasonable rates.

MRSDMM is thus working as a vital link between the milk producers and consumers and working for the economic development and upliftment of the farmers in the rural areas.

Maharashtra Rajya Sahakari Dudh Mahasangh, Maryadit (MRSDMM)

MRSDMM is an Apex Federation of District / Taluka milk unions established to implement the Operation Flood programme in the state of Maharashtra. The main objectives of MRSDMM is to procure milk from the member milk unions at remunerative rates and distribute the same to the consumers at reasonable rates.

MRSDMMis thus working as a vital link between the milk producers and consumers and working for the economic development and upliftment of the farmers in the rural areas.

MRSDMMwas establised on 09th June, 1967.
At present MRSDMM have 86 member unions (25 District † 49 Taluka† 11 Multi-state unions) with more than 20000 primary milk societies & 23 lacs which includes appx. 27000 women members.

MAHANAND DAIRY

is the unit run by the MRSDMM, Mahanand Dairy has made significant growth and progress in the field of productivity improvement, quality improvement, energy conservation, cost control etc. due to sincere and dedicated efforts put at all the levels. The details of significant growth, high lights and achievements of MRSDMM / MAHANAND DAIRY are as under :

ENHANCEMENT IN MILK HANDLING

MAHANAND DAIRY was established on 18th Aug.1983 with a milk handling capacity of 4 LLPD and the capacity was expanded up to 6 LLPD during the year 1997-98.

At present,Mahanand Dairy is distributing 6.5 Lacs litres milk per day in Mumbai with the help of two packing depots strategically located at New Mumbai ( Capacity 3.00 LLPD) & Byculla
(Capacity 1.00 LLPD).

The total sale of milk under Mahanand Brand

The total sale of milk under Mahanand Brand name in the state is 8.5 LLPD including the sale of milk in Konkan, Pune & Nagpur region.

Mahanand Konkan Dairy plant has been established for giving special impetus for development of backward region. At present, we are selling about 30,000 ltrs. of milk per day from Konkan Dairy Project.

Mahanand Pune Dairy Plant

is established to supply Mahanand MIlk to the huge population in Pune city and surrounding area. At present, we are selling about 45,000 ltrs. of milk per day from Pune Dairy Project.

Mahanad Nagur Dairy Plant is establish to provide special impetus to backward region of Vidarbh in general and Nagpur in particular. At present we are selling about 50,000 ltrs. of milk from Nagpur Dairy.

Mahanand Wardha Dairy Plant has been started to provide special support to the Dairy Development activity in Amravati region and the kplant of Wardha District milk union has been taken on rental basis in order to help Rehabilitation of Wardha milk union with financial assistance from Govt. of India and Govt. of Maharashtra. At present, we are selling about 15,000 ltrs. of milk from Wardha Dairy Plant.

Mahanand Dairy Latur :

During the financial year 2002-03 the MRSDMM has taken over the Government Milk Scheme Latur (GOVERNMENT OF MAHARASHTRA) on long term lease basis (30 years). The Mahanand Latur Dairy Plant has been started to provide special support to develop dairy activity in Marathwada region. At present we are selling about 30,000 liters per day of milk from Latur Dairy Plant. Which includes sale at Hydrabad.

Contact

Maharashtra Rajya Sahakari Dudh Mahasangh Maryadit

N.K.M.M. International House, 178, Backbay Reclamation,
Babubhai M. Chinai Marg, Mumbai 400 020. INDIA.

	Mobile Number	Telephone Number	Fax
CHAIRMAN, DUDH MAHASANGH	+91 92237 94687	022 2685 6429	022 2685 8375
VICE CHAIRMAN, DUDH MAHASANGH		022 2685 6258
MANAGING DIRECTOR		022 2685 6196
ADDITIONAL MANAGING DIRECTOR		022 2685 6452
GENERAL MANAGER (MARKETING)		022 2685 6379
OFFICER ON SPECIAL DUTY	+91 92237 98686	022 2685 3238
SPECIAL PROJECT OFFICER		022 2685 6783
DY MANAGER (QUALITY CONTROL)		022 2685 5936
CUSTOMER CARE		022 2685 6572
GENERAL MANAGER (STORE/PURCHASE)		022 2685 6936
MAIN GATE, SECURITY OFFICE		022 2685 6284
PRODUCT MARKETING		022 2685 8198
MARKETING DEPT		022 2685 5933
DISTRIBUTION DEPT		022 2685 5934
CASH CABIN		022 2685 5935
OFFICE FAX			022 2685 6780
BOARD NO		022 2685 6360
BOARD NO		022 2685 6361
BOARD NO		022 2685 6585
BOARD NO		022 2685 6596
BOARD NO		022 2685 6197
BOARD NO		022 2685 6071
Units :
VASHI		022 27880616
KUDAL		02362 223641	02362 223641
KUDAL		02362 223862
NAGPUR		07104 235013	07104 235013
NAGPUR		07104 237237
Latur		02382 222847	02382 220104
PUNE		020 26959363	020 26959345
PIMPALKHUTA		07157 234567
NKM OFFICE		022 22324529	022 22874610

ORGANISATION CHART

INTRODUCTION

Particulars of Organization, Functions & Duties

1) Aims and Objectives of the Organization:

   The District Rural Development Agency (DRDA) has traditionally been the principal organ at the District level to over see the implementation of different Anti-Poverty Programmes. Eradication of rural poverty through successful implementation of different Anti-Poverty Programmes of the Ministry of Rural Development as well as State sponsored plan.

2) Mission and Vision:

   The DRDA has emerged as a pioneer Agency in up-liftment of economic condition of rural poor in rural areas by implementing different scheme/ programs of Govt. and by involving the people as well as PRIs members in the district.

3) Brief History and Background for its Establishment:

   The Bargarh district lies between 20°43' to 21°41' North latitude and 82°39' to 83°58' East longitude. It is one of the western most districts of the State of Orissa and came in to existence as a district from 1st April 1993. It is bounded on the north by the State of Chhatisgarh and on the east by the district of Sambalpur, on the south lies the district of Balangir and Subarnapur and on the west the district of Nawapara. After creation of the new district District Rural Development Agency (DRDA) was constituted as a registered Body under Society Act 1960 and started functioning with effect from 27.08.1993 for successful implementation of different programmes like IRDP, ERRP, NREP, RLEGP, TRYSEM, DWCRA, IAY, JRY, EAS, JGSY, SGRY etc. from. The district has an area of 5837 Sq. Kms. The population of the district as per 2001 census is 134.6 Millions out of which 68.1 millions are male and 66.5 millions are female. There are 12 Blocks and 248 G.P.s are functioning under DRDA.

4) Allocation of Business:

Sl. No.
1	Chief Executive officer of DRDA	Administrative Power/ Financial Power and over all supervision
2	Project Director DRDA	Over all charge of DRDA Activities
3	Addl. P.D. (Admn.)	Remain in charge of Establishment & In charge of P.D. in absence of P.D.
4	Addl. P.D. (Tech.)	Over all in charge of all technical matters dealt in DRDA relating to engineering and works activities
5	Addl. P.D. (Fin.)	To render financial advice to DRDA on financial matter
6	APD (Credit)	Monitoring and credit mobilization with linkage to Bank and SHG groups
7	APD (MIS)	Monitoring and supervision, report/ return
8	APD (Panchyat)	To oversee Panchayat related matter
9	APD (Scheme)	Monitoring & supervision on Poverty Alleviation Programme

5) Duties to be performed to achieve the Mission:

   Regular monitoring, Supervision, Inspection, and Field visit, Review, Conduct of meeting and Call for report return.

6) Details of Services rendered:

   Food security through wage employment, Self-employment, Dwelling houses, rural connectivity, Marketing facility and Creation of Irrigation potentiality.

7) Citizens' Interaction:

   Governing Body Meeting, District Vigilance and Monitoring committee Meeting.           

8) Postal Address of the Main Office Attached/ Sub-Ordinate Office/ Field Units etc.:

District Rural Development Agency, Bargarh,
At/Po/Dist.-Bargarh (Orissa),
PIN-768028

9) Map of Office location:

   Near Private Bus Stand of Bargarh District.

10) Working Hours both for Office and Public:

   Working hour for office work is fixed from 10 A.M. to 5 P.M. No specific time is fixed for public.

11) Public Interaction, if any:

   During the course of their regular tours to different work sites of the block, the officers keep in touch with the general public and try to collect information regarding payment of wages/ or any illegality in execution work in that area.

12) Grievance redress Mechanism:

   Project Director attends the grievance cell of Collector on every Saturday and in his office.

13) Organization Chart:

Introduction

1.     Why process milk?

2.     What problems can arise?

3.     Processing techniques

4.     Pasteurisation

5.     Cooling

6.     Souring by fermentation or acidification

      7.   Creaming

INTRODUCTION

1. Why process milk?

There are many reasons to process milk into dairy products, such as

the following:

1. Many dairy products can be kept longer than fresh milk, therefore

the milk does not have to be consumed immediately.

2.The demand for fresh milk may be limited, and there may be more

interest in dairy products.

3. If the daily amount of fresh milk for sale is limited, it may be more

economical to process the milk into less perishable products, store

them, and sell them later in greater quantities.

4. There may be no market for fresh milk close by, and only preserved

products can be sold at markets at a greater distance.

5. Greater financial gain may be obtained.

Apart from these reasons, it should also be realised that many

population groups in Asia and Africa cannot or can hardly consume

milk because of so-called lactose intolerance. Lactose intolerance

implies that the body is almost or entirely unable to digest the milk

sugar, lactose, which is found in milk. Only small amounts of milk (up

to 200 ml) consumed several times a day can be digested. Dairy

products in which a proportion of the milk sugar is converted during

production, such as cheese, curd, yoghurt and sour milk or buttermilk,

do not cause many problems in this respect.

Preparation of dairy products

Before processing surplus milk, one must consider whether it is

profitable to do so. The processing is not always easy and there may

be losses. For example, a waste product of cheese making is whey,

which contains many valuable nutrients. If the whey is not used, a

valuable part of the milk is lost. Furthermore, while milk is being

processed quality deterioration may occur and it can go off. Only

when milk is drunk immediately can you be sure that nothing is lost.

2. What problems can arise?

Small-scale processing of milk means the processing of small

quantities of milk, up to 100 litres at a time, using simple implements

and as little extra equipment as possible. Processing milk in the tropics

can be difficult because of the high temperatures and high relative

humidity often found there. These conditions present special problems

in choosing the right kind of dairy products. Their storage life must

always be taken into account.

High temperatures are bad for cheese making, especially for maturing

cheeses. High temperatures also cause the bacteria already present in

milk to multiply quickly. Milk sugar then turns sour, leading to the

curdling of milk. However, these lactic acid bacteria are not harmful

to humans.

Thorough cleaning of dairy utensils and equipment is essential.

Anyone handling milk must also pay great attention to hygiene. Lack

of hygiene can contaminate milk with other types of bacteria, which

turn it sour and reduce its storage life. The prevention of

contamination is especially difficult when milk is collected from

various places and processed centrally. Addition of even a small

quantity of infected milk contaminates the total quantity of the milk.

A further problem is the lack of equipment. One has to try to manage

with simple dairy equipment, but even this can be difficult to find for

small-scale milk processing.

Electricity is usually not available soelectric equipment (e.g. for cooling) cannot be used unless a generator is installed. Additives such as rennet for cheese making are often difficult to obtain in the tropics.

The second part of the booklet gives guidelines for heating, cooling

and fermentation and for the processing of cream, butter, ghee, sour

dairy products and cheese.ineffective if the utensils are not clean to start with.

? Disinfect in a chloride or bleach solution after cleaning or shortly

before use. Add 2 tablespoons of bleach per 4.5 litres of water.

It is advisable to use stainless steel equipment, cheesecloth and

wooden utensils. Tools or any other equipment made from aluminium

should not be washed in a strong soda solution, as soda attacks

aluminium. Iron utensils will rust in a strong chloride solution.

Therefore rinse and dry these utensils immediately after cleaning and

disinfection.

If you have no cleaning agents -like soda- or disinfectants, you can

disinfect your equipment as follows:

? Thoroughly clean the utensils using clean water.

? Rinse with a soap solution.

? Dry the equipment on a rack in the sun upside down or rinse with

boiling water.

3 Processing techniques

Milk can be stored longer if it has been processed. Extended storage is

possible if you are able to control the growth of micro-organisms. The

processing technique used will determine the storage life of the milk

and dairy products. The following rules should be followed during the

production, storage and processing of milk.

? Always wash your hands and avoid putting them in the milk if not

necessary.

? See to it that all equipment used during processing is properly

cleaned and disinfected if needed.

? Take care that no dirt particles or insects enter into the milk.

? Try to prevent the use of copper utensils. (Copper can give off

flavours in butter and milk.)

? Do not expose milk to sunlight; store it in a dark place.

? The use of a thermometer is recommended.

? Make sure that milk used for consumption has always been boiled

or pasteurised.

? Never store raw (i.e. unheated) milk if it is not immediately cooled

below 4°C.

? Never drink raw milk because it may contain pathogenic bacteria

like tubercular bacteria and salmonella.

The following processing techniques will be dealt with in this chapter:

? pasteurisation

? cooling

? souring (acidification)

? creaming.

Heating and cooling are in fact ways to preserve milk, but for

convenience we will deal with them under the heading of processing

techniques.

4. Pasteurisation

As you by now know, milk contains certain micro-organisms that can

spoil it. These bacteria grow best at temperatures between 10°C and

40°C. It is therefore important to cool milk as quickly as possible.

This can be difficult in the tropics if no cold water or refrigerators are

available.

Most bacteria will be destroyed during heating. The most effective

temperature depends on the heating time. In other words, heating for a

longer period at a lower temperature can be as effective as heating for

a shorter period but at a higher temperature.

a Direct pasteurisation of milk in a saucepan (method A below)

b Pasteurisation of milk in bottles (method B below)

Pasteurisation improves the safety and storage life of a product, while

the taste hardly changes and the loss of vitamins is minimal. A

distinction is made between low and high pasteurisation (see table 2).

Although high pasteurisation initially kills more bacteria, the resulting

milk can usually not be kept as long, because the high pasteurisation

temperature stimulates spores of some bacteria to germinate.

Moreover, the taste of high pasteurised milk has more or less the

flavour of boiled milk. Pasteurised milk can be kept for about one

week at 4-6°C if no re-infection takes place.

The pasteurisation temperature to be used depends on the product to

be made of the milk.

? Low pasteurisation is used for milk for direct consumption and

cheese.

? High pasteurisation is used for yoghurt, butter and kefir.

Time Temperature Remarks

30 Minutes 63°C Quantities >5 Litres

3 Minutes 68°C Small Quantities

Low Pasteurising

20 Seconds 72°C *) Industrial Equipment

High Pasteurising 2 Minutes 82°C

20 Seconds 85°C *)

*) Continuous Flow System; Not For Small-Scale Processing

If there is no thermometer to measure the exact temperature, heat the

milk to its boiling point.

Pasteurisation methods

The following method A is suitable if you are able to accurately

control both temperature and time. Method B is more hygienic, if the

exact temperature of the milk is unknown.

You will need:

? raw milk, a heat source, a saucepan with a thick bottom that is

smooth on the inside, a thermometer and a means of cooling the

milk that has been heated

? for method A: a clean wooden spoon

? for method B: glass jars with lids or bottles with tops, or plastic

bags and sealing equipment.

Processing techniques 31

Method A

Put the milk in a clean saucepan and heat it to 68°C, stirring

continuously. Keep the milk at that temperature for at least 3 minutes.

Method B

Clean the glass jars with lids or bottles with tops. Fill them with milk

and close the lids. Submerge the jars and bottles in a large pan filled

with water. Heat everything to 80°C and keep it at that temperature for

at least 10 minutes.

When using method A, let the milk cool down as quickly as possible.

The best storage temperature is 4°C. The proper storage temperature

for a soured milk product or cheese can be found in chapters 6 and 7.

If you are using method B but are not able to maintain a constant

temperature of 80°C, the best alternative is to heat the water in the pan

until it boils and keep it boiling for some time. It is important to store

the pasteurised or boiled milk at 4°C. At this temperature it can be

kept up to one week. Handle the boiled or pasteurised milk with care

to prevent re-infection.

5. Cooling

Storing milk at a low temperature will greatly reduce the growth of

bacteria. Bacteria develop much slower in cold milk. The best storage

temperature is 4°C. If this temperature cannot be achieved, store the

milk in a dark place at the lowest temperature possible: see table 3.

Without cooling, raw milk will spoil within a day.

Put the hot pasteurised or boiled milk in a clean container (the high

temperature will disinfect the container). Let it cool down as quickly

as possible, preferably in a large pan with cold water (refresh the

water if it warms up). The best temperature for storage is 4°C. Cooling

down in air, e.g. in a cold cellar or a refrigerator is very ineffective as

the transfer of cold by air is very slow. If you use a pan with cold

water make sure that no water enters into the milk because it would

contaminate the milk again. Add ice cubes to the cooling water, if

available. Stir both the water and the milk during cooling with a clean

spoon, using different spoons. Figure 10 shows how to cool milk.

As mentioned above, properly pasteurised or boiled milk can be kept

for about one week if stored at 4°C. At 10°C it will spoil quickly; if it

is 15°C or warmer, it should be consumed the same day (see table 3).

 6.Souring by fermentation or acidification

Another way of increasing the shelf-life of milk is to ferment it into

soured milk products. Part of the milk sugar is converted into lactic

acid by bacteria, for example by the yoghurt bacteria Streptococcus

thermofilus and Lactobacillus bulgaricus or the bacteria that grows at

room temperature Streptococcus lactis.

Fresh raw milk can be left to sour spontaneously, but then you cannot

control which bacteria are growing. It is better to sour the milk with

the help of specific lactic acid bacteria as a starter culture after the

milk has been pasteurised. Quality and taste are influenced by the

products that the different lactic acid bacteria produce.

7. Creaming

Cream is made from the fat that rises to the surface of cow milk. A

layer of fat forms on the surface of the milk after it has been left to

stand for at least half a day. After a day this layer contains about 20%

fat. The simplest way of collecting it is by skimming it off the top of

the milk. Sheep and goat milk do not cream easily. You will need a

creamer or centrifugal separator to obtain good results. You should be

able to get about 1 - 2 litres of cream from 10 litres of milk.

The skimmed milk which remains after the removal of the cream is

still very nutritious, because it contains nearly all the protein of the

milk. You can either drink it or use it for the production of sour milk

or cheese.

Sour (fermented) cream and sour (fermented) milk are produced by

incubation of inoculated fresh cream or fresh milk. A culture of lactic

acid bacteria is used for inoculation of the fresh milk or the fresh

cream.

Butter (80% fat) and buttermilk are made by churning cream or milk.

One hundred litres of milk with a 4% fat content produces 20 - 30

litres of cream, which yields about 4 kg of butter. However, butter is

34 Preparation of dairy products

not an important product in tropical countries because it melts easily

at high temperatures and it is expensive. There is generally little

demand for butter. Butter and cream can be used to make ghee. Ghee

keeps better than cream and butter as it contains practically no

moisture; it is almost pure milk fat.

Appendix 1: Measures

1 drop = 0.05 ml

20 drops = 1 ml

1 tablespoon = 15 ml

1 cup = 250 ml

1,000 ml = 1 l

 

 

 

ERP definition :

• It is a company-wide computer software system used to manage and coordinate all the resources, information, and functions of a business from shared data stores.
• ERP relates to the integrated software infrastructure that supports the entire company business process.
• ERP refers to a view of a company and all its parts as connected whole, rather than small silos of activity

ERP advantages and disadvantages

Advantages

• Allows easier global integration (barriers of currency exchange rates, language, and culture can be bridged automatically)
• Updates only need to be done once to be implemented company-wide
• Provides real-time information, reducing the possibility of redundancy errors
• May create a more efficient work environment for employees^[2]
• Vendors have past knowledge and expertise on how to best build and implement a system

Disadvantages

• Locked into relationship by contract and manageability with vendor - a contract can hold a company to the vendor until it expires and it can be unprofitable to switch vendors if switching costs are too high
• Inflexibility - vendor packages may not fit a company's business model well and customization can be expensive
• Return on Investment may take too long to be profitable
• Implementations have a risk of project failure^[2]

Process Automation and Integration

 

At eDoodh Solutions we leverage our expertise and experience in the areas of software development, engineering, system integration, and data management to market a variety of solutions and services: System Integration, Test and Measurement, Systems, Software Development, Network Infrastructure, Database Design, Managed Staffing, FDA Validation, Training / Consulting.

Strengths include automated test, robotics, assembly, vision, instrumentation / Cleanroom and aseptic equipment / GMP, ISO, UL, CE, FDA / Software development (PLC and PC controls, LabVIEW, motion control, HMI, .NET, etc)

 

eDoodh Solutions  has two business units covering the company’s main areas of concentration:

• design and integration of Dairy automation and information systems, including industrial automation,   prototyping, electronics, electrical and mechanical installation;
• full range of custom software development and IT outsourcing;

Dairy automation

We offer a complete range of automation solutions ranging from defining an overall strategy to implementation, from separate components to integrated systems and software. We design both hardware and software machine controls that govern all phases of the Milk process and integrate components from various vendors to provide the optimum-engineered solution to accommodate our clients’ individual needs.

We provide integrated Dairy automation systems based on unique design, latest software and technologies, most efficient and quality hardware available in the industry combined with a high level of customization for our clients. Our talented staff are capable of designing and integrating industrial automation and control systems that meet most complex customer specifications. Present day industrial development demands full scale integration of Dairy automation and IT technologies and we are proud to say that our extensive experience in both Dairy automation and IT fields allows us to offer our clients state-of-the art Dairy automation systems.

Environments including:

• Automation of plant and machinery

• System design and integration

• Standard and medium voltage drives

• Controllers

• Industrial components

• Input/Output (I/O) modules

• Computer numeric controllers (CNC)

• Program logic controllers (PLC)

• Electrical assemblies

• Electrical installation

• Control systems integration

• Consulting and engineering services

• Human-machine interface/visualization software (HMI/SCADA)

• Information systems software

• Process monitoring and control software

• Automation

Mahanand introduces eDoodh technology

In a bid to keep up with the change in the latest technology in dairy industry, one of the leading co-operatives in the state, Maharashtra Rajya Sahakari Dudh Mahasangh Maryadit (MRSDMM), Mahanand Dairy in short has performed the modernisation of the milk processing plant at Goregaon unit in Mumbai last week.

The modernisation was done by the implementation of an Integrated Computerisation/ Automation solution using a plant-wide network of PLCs and PCs over 10/100 mbps fast Ethernet

The complete project is done on turnkey basis by M/S eDoodh Solutions (India), which is an Indian company with the technical base in Houston (USA), with mutual support of technical and engineering staff at Mahanand.



Mahanand is the first dairy in the country to be computerised with the existing facility and equipments. eDoodh has successfully introduced the computerisation of all critical processes like batch formation, pasteurisation, homogenisation and CIP with modernisation of equipment.

Maharashtra Rajya Sahakari Dudh Mahasangh, Maryadit (MSRSDMM) is an apex federation of District/Taluka milk unions in the state of Maharashtra. Since its establishment it has gained the reputation of a federation dedicated to quality of milk and development of milk farmers from each and every corner of Maharashtra state. At present MRSDMM has 81 member unions with 24,000 primary milk societies. Total members registered are 24 lakh, which include approximately 25,000 women members.

How does it work?
 With this the entire processing operations are carried out from an air-conditioned control room. Information of milk at various stages are closely monitored, recorded and controlled by the computers and PLCs. On top of this there is an umbrella MIS (Management Information system) to maintain the record and communication to the laboratory for quality assurance. Automation is introduced at various stages like milk storage in silos, centralised monitoring and control of all pasteurisers (maintained exactly at required levels and ensures proper pasteurisation). Milk silos are connected with the quality control laboratory for on-line approval process.

Cleaning of one lakh litre capacity silos is also done by computer. In ordinary systems, it is difficult to monitor cleaning and maintain quality standards. At Mahanand, all parameters such as concentration of cleaning agents and temperature of water to be used for rinsing are stored in the system with no room for error. In totality complete system offers qualitative benefits and apart from this increased working efficiency, saving in energy, water and recovery of cleaning solutions.

 

Software Development—

Our information technology services and business solutions are aimed at helping dairy industry of all sizes grow and compete in the new world of business with our key area of specialty centered on:

• Advanced database architecture, analysis and programming  
• Internet/Intranet/Extranet architecture and deployment
• Development of information systems and mission-critical applications
• Full cycle development of web and client/server applications.
• Custom application development

eDoodh Solutions offers unequaled expertise in designing medium to large scale software systems, combining existing systems with the newest versions of technology, building web-enabled applications and by providing you cost saving solutions through IT consulting and IT outsourcing. We bring to you a wealth of experience in all phases of the software

• Electrical installation • Control systems integration • Consulting and engineering services • Human-machine interface/visualization software (HMI/SCADA) • Information systems software • Process monitoring and control software • Automation

 

HTST Pasteurizer Automation—

ABSTRACT

_A high temperature, short time (HTST) pasteurization system is equipped with electronic sensors to determine the temperature.

A computer for data acquisition was wired to the sensors to monitor and to record processing conditions related to public health. The processing conditions are stored in safety files on the hard drive of the computer and can be transferred on a tape drive and stored.

Enables to calculate means, standard deviations and average deviations.

Our system will work in synchronization with the computer to control the steam and chilled water valves. The whole solution with record the pasteurizer parameters, enable us to monitor on the computer monitor and in-turn control the most critical valve movements.

 

BENEFITS OF PASTEURIZER  AUTOMATION

1. Conservation of energy for heating milk. 

2. Adequate and proper pasteurization will improve the overall quality of milk. 

3. Reduces fluctuation in heating temperature will improve the nutritional quality of milk. 

4. Control the chilled milk out let valve (which is delivering milk to silos) as per the specified range of temperature and if milk will be at higher temperature then it will divert milk. 

 5. No chances of higher temperature milk delivered to silo will improve the out let and packaging temperature of milk results into more shelf life of milk.  

6. Reduces the refrigeration energy requirement as the heating temperature of milk doesn’t go beyond the specified temperature range. (due to decreased SETPOINT and  narrowed down range of heating) 

6. Saving of Heating and chilling energy will decrease the cost of per litre processing of milk. 

7. Steam valve and chilled milk out-let valve will be available on the computer screen and a very minute change in the valve position will be seen in the line graph. 

8. Sophisticated computer and Centralized PLC based controller in-place of individual PID for each pasteurizer.

 Cheese Pasteurization Objective:

To improve yield and quality of cheese

This can be achieved by lowering pasteurizer temperatures resulting in less denatured whey protein binding to casein and thus allowing more rennet activity. The goal is to improve the setting in vats and synersis, as well as improving the whey yield.

 CIP (Clean-In-Place) Automation

    BACKGROUND

CIP (cleaning in-place) is the commonly used method for plant cleaning during the production process where hygiene is, of course, paramount. Process piping and vessels used in the dairy and food industry require        periodic Cleaning without disassembly to remove residue from previous batches and to sanitize both the process piping and vessels. The cleaning can involve alternately

BENEFITS

 A modern CIP system will not only save money in terms of higher plant utilization but also due to significant savings in CIP liquid (by recycling cleaning solutions), water (the system is designed to use the optimum quantity of water) and man-hours.

 Improved cleaning effectiveness

 Enhanced product quality

 Documentation and Process Optimization - Allows simultaneous recording of measured values and switching statuses and thus creates the necessary transparency for process optimization. Recording of measured data is supplemented by a database-supported event log with practice-oriented evaluation features. The history recorded is optimally suited for tracking individual batches or entire productions.

 Less downtime, less resource consumption, and an all-round cleaner and better functioning plant.

 Provides recycling capabilities, resulting in huge cost savings for: water, hot water, caustic, sanitizer and acid

 Recipe based system supports different types of cleaning requirement in typical dairy plant and cleaning objectives can be re-defined as per requirement or seasonal implications to optimize the returns.

 

SWOT Analysis

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Restaurants ought to make bigger napkins, since some of the most productive business ideas seem to come to mind over a meal. The SWOT analysis technique lends itself to napkin planning and snapshot insights. To conduct a SWOT analysis, draw a vertical line in the center of your napkin (or whiteboard or flipchart), intersected by a horizontal line. Now you have four quadrants where you'll sketch your company's situation.

Strengths	Weaknesses
Opportunities	Threats

Though a great deal of research may lie behind what's in each box, keep it simple and incisive. Collecting these facts and ideas together in one place energizes you to see the big picture. Use it as a brainstorming tool. A strategy formation tool. Note that the first pair of categories -- strengths and weaknesses -- refer to your company's INTERNAL nature, while the second pair of categories refer to EXTERNAL opportunities and threats.

Strengths

In the first box list all the strengths your company possesses. Don't be modest. Spell them out. If you do this with others, you might begin by brainstorming words that characterize your company and writing them down as fast as people say them. Then use those ideas to construct a profile of your company's strengths.

Weaknesses

In the second box list weaknesses, areas your business lacks or doesn't have the personnel to cover well. Be honest. It's better to face the bad news now rather than construct an unrealistic marketing plan that is doomed to failure.

Opportunities

The third box is for opportunities. When you look at the market (and we're looking particularly at the Internet market in this series), what do you see? What AREN'T your competitors doing that customers need? Look for gaps. Of course, this is related to a competitive analysis; none of these elements of a marketing plan stand alone; they're all interrelated. Gaps may not last long. What you see as an opportunity today may not exist in three months. A SWOT analysis is only a snapshot in time, not a permanent document.

Threats

The final box is to list threats to your business. What trends do you see that could wipe you out or make your service or product obsolete? What are your competitors doing to push themselves ahead? What new dot-com start-up is trying to move into the market?

Here's an example of how a SWOT Analysis might look for a fictional animal greeting card site, CrawlyCards.com, specializing in pictures of ground-clinging creatures such as slugs, snails, and puppydog tails.

Strengths ·         Unique idea, no one else is even close ·         Strong artistic team includes some of the finest slug and insect illustrators in the country ·         Excellent animation abilities ·         Source of inspirational card inscriptions for all occasions ·         Experienced and innovative company officers.

Weaknesses ·         Small opt-in customer list, most site users seek to remain anonymous ·         Few advertisers interested in this strangely targeted market ·         Perl script that runs the site is slow and needs to be rewritten in a compiled language ·         Lack of interest from venture capitalists. ·         Single stream of revenue is advertising, and that is slim pickin's.

Opportunities ·         No real competitors in our precise space. ·         Much traffic from students at UC Santa Cruz (Banana Slug is their mascot) sending cards to each other. Possible joint venture with alumni association and theOfficial Pacific Northwest Slug Page http://www.tammyslug.com ·         Seek advertising from French restaurants and their suppliers. ·         Possible books sales such as: Slugs and Snails (Minipets), Field Guide to the Slug, and Creepy Crawly Cuisine: The Gourmet Guide to Edible Insects. ·         Possible sales of Turbo Snails to browse algae in fishtanks ·         Partnership with CyberSlug Adoption Center ·         E-commerce venture selling scarab jewelry ·         Possible advertisers among pet supply and fish supply stores, bug jewelry manufacturers ·         Possible affiliate program with snail bait companies ·         Possible cross promotion with Conchologists of America

Threats ·         Chemical companies are producing more effective snail bait that may destroy gastropod populations in our lifetime. ·         Large card sites such as Blue Mountain (http://www.bluemountain.com) might want to take over the slug and mollusk traffic and edge us out.

Obviously this company has some real problems -- no effective revenue model -- but at least they're looking at alternatives. This is what a SWOT analysis can do for you, and may be the germ of an idea that will revolutionize the snail and slug card business as we know it.

(To those of you from a different culture, this example is a joke. Please don't take it seriously, just an example of Yankee poor taste. :-) It helps lighten up an otherwise dull subject.)

Mahanand breaks new ground with ATM, Fresh Cafe
Saturday, October 29, 2005
Bosky Christopher

Maharashtra Rajya Sahakari Dudh Mahasangh Maryadit, better known as Mahanand Dairy, has come up with the first-ever Any Time Milk outlet at Gokuldham complex in Goregaon, a northern suburb of Mumbai. Two weeks after its introduction, it is too early to predict the popularity of such an outlet. Usually associated only with milk, the local milk co-operative plans to carry out a makeover of the Mahanand brand with the launch of its very own 'Fresh Cafe' coffee shop and eatery on New Year on the periphery of its dairy at Goregaon. The outlet is located in a fast-developing area bordering the Western Express Highway. R A Rajeev,Managing Director, Mahanand Dairy, shared his views on its very own Any Time Milk outlet and spelt out his plans for the makeover of the Mahanand brand, in an exclusive interview with Bosky Christopher of Food & Beverage News.

The Any Time Milk outlet sounds like an innovative concept. What has been the response since its inception? 

The bulk vending system for milk is not a new one. It is already there in places like Delhi and Kolkata. So the concept of Any Time Milk is known. When we were thinking of alternatives to pouch packing of milk and reaching out to the consumers directly by eliminating the middlemen so that the problem of adulteration is also taken care of, we thought that the bulk vending system should be a good alternative. But when we studied the consumer behaviour in Delhi and Mumbai, we came up with a lot of differences. We were a little apprehensive of the fact that Mumbai consumers may not like to visit a milk booth for collecting milk. If we have the same system of inflexible timings for Mother Dairy bulk vending system as it happens in Delhi with two hours in the morning and two hours in the evening, Mumbai consumers may not like it. We decided that in order to be more consumer friendly we should adapt to the consumer behaviour of Mumbai where people coming from home and going back home is not a uniform pattern. Some of them leave very early in the morning and return home early. Some reach home very late. So we thought of making any time milk centre where, whenever you have time you can come and collect your milk. That may give the flexibility and consumer acceptability also to our bulk vending system. So we termed it as Mahanand ATM. Introduced on October 10, it is now picking up and has now reached a sale of 150 litres a day, which initially was around 80 litres. Gradually, the acceptability is increasing. 

How does the system work? 

Through this system, processed milk is transported and stored at chilled temperature at the outlet. The automated machine will deliver specific and accurate quantity of milk based on computerised programme.

Instances of milk adulteration have been plaguing supplies in the city of late. What initiatives are taken to rule out this possibility? 

There will be no middlemen between the Mahanand Dairy and the consumers. The milk tanker would pour milk straight into the outlet, making any intervention impossible.

Are there any plans to open more such outlets? 

The milk federation has already got offers for opening such outlets at Kurla, Dahisar, Mira Road and Bhayander. But we are studying the possibilities, as it also needs some investment. We want to select areas in the same direction so that our milk tankers do not have to make diversions.

While studying the consumer behaviour, we are also planning to introduce one or two near the slums shortly so that we can see the response better.

The price of milk has been kept at Rs 14 per litre, which is low in comparison with the normal cost of milk in Mumbai. So, is it not a loss making proposition? 

It's not. The market price is Rs 15. We have reduced it to Rs 14. Through this system, we are cutting the cost of cold storage and there are no plastic pouches involved too as consumers have to come with their containers. So the cost reduced there has been rightly managed at the outlet. We will recover our costs.

What is the capacity of the outlet? Can the outlet be refilled promptly whenever required? 

Though the outlet capacity is 1,000 litres, it is estimated that initially the consumption will be 500 litres, which will go up later. With the outlet being close to Mahanand's plant, the outlet can be refilled promptly whenever required.

It is a pilot project started on experimental basis. So, we are still watching consumer behaviour. Besides, we are selling a lot of milk products from that booth.

The experimental booth has been established at an investment of Rs 7 lakh. It provides milk from 5 am to 11 pm. If there is a demand we will extend the night timings. We are also getting feedback from consumers. For instance, providing containers for people going back home from railway stations or bus so that they need not bring their vessels to fetch milk. So, we are planning to stock containers which they can buy and use.

Usually associated only with milk, are you contemplating a makeover of the Mahanand brand? 

We have firmed up our plans to inaugurate Fresh Cafe on the New Year. It will be a complete eatery centre, with a range of milk products, coffee, tea, pizzas, sandwiches, and will include an entertainment zone for children. The Fresh Cafe outlet will tap a growing retail market for eateries and cafes, besides serving as a platform to market a range of Mahanand products.

With a seating capacity of 60, the place would have waterfalls, fountains, and a children's play station. It would also have Any Time Money outlet. The children's entertainment area would include a computer with an animated package, which would transport the children into Mahanand's "World of milk".

The location is very strategic because it is right on the Western Express Highway. It adds to the overall beauty and environment of the dairy. It will also be a centre of attraction for people passing through the highway.

Mahanand has also plans to launch its very own brand of ice-cream in the future along with a Fresh Cafe range of flavoured milk and milk products.

What will set your very own coffee shop and eatery apart from the rest? 

I hope that it stands out on its own. The concept is completely different here. The trend now is away from Pepsi and Coke. The trend is towards healthier products. Fresh Cafe will only have milk products. It will also set us apart from general restaurants. Anybody who is diabetic and people with cholesterol problem can also come here and have food. The emphasis will be more on the quality and health. The mainstay of this will be a milk bar where you can make milk shakes of your own choice. The idea is to enjoy eating while at the same time healthy entertainment for kids in good environment. It will be value for money and one can spend quality time.

Are there any plans to brand Fresh Café and sell it as a franchise? 

The fully run and operated Fresh Cafe will seek franchises for private businesses to open other Fresh Cafes in the city, with each having the same features across the board.

Fresh Café is a concept where it is a fast food restaurant. The USP of which is 'Swadful Sehatful' - tasty and healthy. Everything will be made in-house. We have also developed special bread for the pizzas and Fresh Café is developed on the lines of McDonald's, Pizza Hut where it will be a branded shop and it can also have the potential to be developed into franchises to begin with in Mumbai and also nationally. 

What is the volume handled by the state milk co-operative federation? 

Sale of milk in a day in Mumbai is around 6.75 lakh litres a day. It keeps on fluctuating. We also have presence in Karnataka, Andhra Pradesh, Gujarat, Goa and some parts of Madhya Pradesh. 

Any other projects in the pipeline? 

We are planning the launch of tetrapacks, which will happen next month in Mumbai first, and other parts of the country gradually. We are bringing flavoured milk, lassi, chaas, skimmed milk and cow milk. With tetrapack coming in, it will be easier for us to expand our reach to all the other metros.

Will the ban on plastic affect you adversely? 

If the ban on plastic is going to affect the whole sector, then we will also be affected uniformly. It will be a level-playing field for everybody. There should not be negative externality attached to that. There should not be any agency that is finding some loopholes somewhere and supplying milk at lesser price or in low material packing. If that is not there and the ban or rule is uniform for everybody then we don't mind following the rules.

What are the alternatives ahead of you? 

There are alternatives available in the market. The market also has to develop and grow. At present milk is not being distributed through 100% cold chain and that is one of the disadvantages. The cold chain is broken during distribution and retailing, which is not good. So, if there is a better marketing system, better packing system - it is always welcome. I take it that way. Any crisis is an opportunity for the consumer, for the industry, for the society. So, I look at it as an opportunity.

Projects

Ongoing Projects

Automatic Bulk Vending
TMRSDMM has started milk distribution through automatic bulk vending system to cater the need of middle class family with the name ATM (Any Time Milk) at Gokuldham.
Tetrapak Project
MRSDMM has planned to start marketing and distribution of long life milk & milk products in Tetrapak such as plain cow milk, skim milk and flavoured milk. Tetrapak milk & milk products shall be marketed throughout the country with well knitted marketing & distribution network.
Solar Project at Latur
At MRSDMM, the work of prestigious "Solar Project" is going on with the assistance of MNES, New Delhi and I.I.T., Mumbai. The project work is at advance stage of completion and after completion of this project, milk pasteurize shall be run without using fuel (furnace oil, Diesel etc.) which shall be proved as boon to Dairy Industry.
Computerization
Modernization of Mahanand dairy is future plan and as a part of it computerization is considered as a first step. Training is being given to staff.

Josh Milk on Railway Stations
Mahanand has introduced Josh Milk (Flavour Milk) on Railway platforms from 10th January 2006.

INSENTIVE DAIRY DEVELOPMENT PROJECT
This is 100% centrally financed scheme, which is planned to be implemented by Dudh Mahasangh App. Rs. 3.00 Crores would be available to the Backward Hill area district of Nandurbar, Nanded, Nagpur, Latur & Amravati District.

Conclusion

We joined as a part of implementation team for ERP. We tried to design the work solutions to the employees of Mahanand to best of our knowledge. We learnt a lot from actual shop floor work to what it takes to develop a product from scratch in an engineering firm. We again would like to thank Mr. Mr. JADHAV for the support and mentorship during  the duration of internship.