katraj

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A

PROJECT REPORT

ON

PRODUCTION PROCESSAT

KATRAJ DAIRY INDUSTRY

PRESENTED BY

ROLL NO:

SUBMITTEDTO

UNIVERSITY OF PUNE.

IN PARTIAL FULLFILMENT OF

BACHELOR OF BUSINESS

ADMINISTRATION.

(2011-2012)

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ACKNOWLEDGEMNT

First and foremost I would like to express my heartfelt gratitude to the staff

members of the katraj industries pvt.Ltd. for providing me with much of their

cooperation precious time valuable resources on completing this project report of

the production process of katraj dairy.

From the bottom of my heart I express special thanks to respected madam

Sabiha.N Shaikh for constantly guiding me and boosting my moral and the

valuable and the unstated help rendered by my friends in completion of this project

and also we are grateful to Dr.Vivek Kshirsagar (managing director), Mr.

P.R Thorat (deputy manager), Mr Bapu Saheb More (assistant manager)

who have sacrificed their valuable time and provide us information regarding the

production process of Katraj dairy industry.

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PREFACE

In B.B.A degree there is subject namely project work which we have to do

during our academic year for which are required to visit a particular

organization, this gives us the practical knowledge about the course.

Being a student of management, I also got this opportunity to undertake the

project work. It is going to be highly beneficial for my master degree as well

as in job market.

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INDEX

S.NO. TOPIC PAGE

NO.

CHAPTER 1. Introduction

1.1 Objective

1.2 Scope

1.3 Assumptions

1.4 Limitations

1.5 Significance Data collection

CHAPTER 2 Company profile

CHAPTER 3 Review of literature

CHAPTER 4 Data analysis

CHAPTER 5Conclusion & suggestion

Bibliography

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(CHAPTER 1)

INTRODUCTION

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Introduction

Dairy farmers are in the business of producing food. They aim to ensure that

the safety and quality of there raw milk will satisfy the highest expectations

of the food industry and consumers. On farm practices should also ensure

that milk is produced by healthy animals under acceptable conditions for the

animals in balance with the local environment

The overreaching principles applying to the production, Processing and

handling of milk, milk products are ;

From raw material product to the point of consumption, all dairy

products should be subject to combination of control measures .

Together , this measures (good agricultural practice-GAP and good

manufacturing practice-GMP) should meet the appropriate level of

public health protection .

Good hygienic practices should be applied through out the production

and processing chain so that milk and milk products are safe and

suitable for the intended use.

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objectives

To know about the production process in a practical manner.

To make a project research regarding it process with all others related

aspects.

To improve the background knowledge of the students regarding the

production management.

To give opportunity to students express their talents and capabilities

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Scope and significance

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Limitations

These studies mainly focus on the production of milk and we are notaware of its qualities and cost of production.

The information collected from the internet is not sufficient for the realstatus view of the industry.

The fact in the figures provided in the data may be approximation and notaccurate and also statistics provided could have changed with time.

The policies and the production process may get altered as per the as perthe companies term and policies.

The time allotted was insufficient to cover vast studies regarding thesubject matter.

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CHAPTER (2)

REVIEW OF THE LITERATURE

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Introduction production management

Planning, implementation, and control of industrial productionprocesses to ensure smooth and efficient operation. Productionmanagement techniques are used in both manufacturing and serviceindustries. Production management responsibilities include thetraditional five M's: men and women, machines, methods, materials,and money. Managers are expected to maintain an efficientproduction process with a workforce that can readily adapt to newequipment and schedules. They may use industrial engineeringmethods, such as time-and-motion studies, to design efficient workmethods. They are responsible for managing both physical (raw)materials and information materials (paperwork or electronicdocumentation). Of their duties involving money, inventory control isthe most important. This involves tracking all component parts, workin process, finished goods, packaging materials, and generalsupplies. The production cycle requires that sales, financial,engineering, and planning departments exchange informationsuchas sales forecasts, inventory levels, and budgetsuntil detailed

production orders are dispatched by a production-control division.Managers must also monitor operations to ensure that planned outputlevels, cost levels, and quality objectives are met.

Definition of production management

Administrative discipline for the effective use of resources in on-

schedule production of the targeted number or quantity of endproducts that meet the specified cost, performance, quality, andwaste requirements.

Production management is the process of planning, organizing,Directing and Controlling the activities of the productions functions.

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Objectives of production management

Primary objectives:

Manufacturing costs

Products quality

Manufacturing schedule

Secondary objectives

Machinery and equipment

Materials

Man power

Manufacturing services

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Scope

Long term decisions

Product selection

Product design

Plant location

Plant layout Capacity planning

Short term decision

Production planning and control

Inventory control Quality control

Cost reduction

Maintenance and replacement

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(CHAPTER 3)

PROFILE OF THE COMPANY

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Excellence in our line of businessPromotes your growth.

THE COMPANY

Katraj was incorporated in 1960 with an intension of providing an organizedfacility of milk collection for the village level farmers situated in Punedistrict. Katraj Dairy started with milk collection of about 0.30 lakh (30.000)litres in the first year of operation and today, has steadily grown to over 3.25lakh (0.32 million) litres per day and has a financial turnover of over Rs.150crores (Rs.1500 million / US$ 33 million).Katraj with its six plants spread almost all over the district has an installedmilk handling capacity of over 5 lakh (0.50 million) liters per day. The main

plant of Katraj is equipped with Pasteurizer, homogenizer, Cream separator,Ghee processing, automatic packing of products and other quality testing

devices and well equipped labs. Katraj has an installed processing capacityof 2 lakh (0.2 million) liters per day.Katraj with its six plants spread almost all over the district has an installedmilk handling capacity of over 5 lakh (0.50 million) liters per day. The main

plant of Katraj is equipped with Pasteurizer, homogenizer, Cream separator,Ghee processing, automatic packing of products and other quality testingdevices and well equipped labs. Katraj has an installed processing capacityof 2 lakh (0.2 million) liters per day.Katraj manufactures / Distributes products like Pasteurized/ Homogenized-Cow/ Standardized Milk, Toned Milk, Cream, Ghee, Shrikhand,Amrakhand, Malai Paneer, Matka Dahi, Flavored Milk, Lassi, Jeera Tak,Table Butter, Milk Powder, Softy Ice cream and in the near future plans tointroduce sterilized products like bottled flavored milk.All these products are available at Katraj owned parlors at various locationsin Pune City and through appointed distribution and retailing circuits. Verysoon, Katraj plans to introduce an online ordering system for its distributors/

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retailers and consumers.

Katraj products have been in use in thousands of homes in Pune since 1961.Katraj Milk, Katraj Ghee, Katraj Shrikhand, Katraj Softy Ice cream andKatraj Milk Powder have made Katraj a leading food brand in WesternMaharashtra. Today Katraj is a symbol of high-quality milk products sold at

reasonable prices, the genesis of a vast co-operative network triumph ofindigenous technology, the marketing savvy of a farmers' organization.

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BOARD OF DIRECTORS

2010---2013

Shri. Rambhau SambhaTule

Chairman

02119-223177 / 9890880977

Shri. Ramchandra Dhondiba

Thombre

Shri. Gopalrao Ramchandra

Mhaske

Shri. Balasaheb Mahadev

Shete

Director Director Director

25380671 / 9822094908 26990031 / 9822088558 02135-284240 / 9881393931

Shri. Balasaheb JayvantraoDhamdhere

Director

24479422 / 9822376592

Shri. Vishnuseth DharmajiHinge

Director

24213424 / 9822502963

Shri. Balasaheb ShankarNewale

Director

02114-266088 / 9850039415

Shri. Ramesh Vishwanath

Bhujbal

Director

26685422 / 9766188088

Shri. Sandeep Maruti

Jagadale

Director

02115-278130 / 9850828030

Shri. Diliprao P. Thopte

Director

9822010599

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Shri. Narayan B. Phadke

Director

9764877009

Shri. Balasaheb K. Khilari

Director

9011079696

Shri. Bhagavan Pasalkar

Director

9850107494

Shri. Arvind ChintamaniMormare

Director

9421922359

Shri. Arun C. Chambhare

Director

9822960439

Smt. Keshartai S. Pawar

Director

9822833444

Smt. Surekhatai B. Bhadale

Director

9850968454

Shri. M. A. Muktadeer

R.D.D.O. , Pune

9422130119

Smt. Vaishali B. Nagawade

Mahanand Representative

9422359284

Shri. Ranjan Lakhe

Regional Registrar Co-op Soc. Milk, Pune

922637411

Shri. Anil S. Sonawane

Special Auditor, Class- I

9822294364

Dr. Vivek HinduraoKsheersagar

Managing Director

9970066786

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Objectives

To know about the production process in a practical manner.

To make a project research regarding it process with all others related

aspects.

To improve the background knowledge of the students regarding the

production management.

To give opportunity to students express their talents and capabilities

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DATA COLLECTION

PRIMARY SOURCE

The data was collected by visiting the plant and by interactingwith the staff members of the plant.

SECONDARY SOURCE

The data was collected from the website of the organization.

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(CHAPTER 4)

PRODUCTION PROCESS

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Flow chart??????????????

MILKING AND COLLECTION

The production process starts with the milking and collection. With an

intention of providing an organized facility of milk collection for the villagefarmers situated in Pune district.Today the collection of milk is more than 1500,000 liters per day. The milkis stored in the village at a chill place

TRANSPORT

After the collection of the milk, it is stored in the chilled room at village themilk is transport to KATRAJ DAIRY INDUSTARY.

PROCESSING:

After the transportation, the milk is processed at the KATRAJ dairy industry.Different testing is done at dairy, the protein, sugar and fat is tested. The sugaris tested by Lactometer and the fat is tested by pedometer.

PASREURIZATION

The term pasteurization refers to the process of heating each & every

particle of milk to at-least 63 C for 30 minutes, or 72 C for 15 seconds in

approved and properly operated equipment. After pasteurization the milk is

gradually cooled to 5 C or below.

Homogenization

Homogenization refers to the process of forcing the milk through a

homogenizer with the object of sub dividing the fat globules

Consumer: after the mention process (like: collection and milking,

transport, processing, packing, distribution) it reaches to consumer. Consumer

is the person one who consumed or uses the product

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PRODUCTS

Amrakhand

Cream

Ghee

Lassi

Matka dahi

Milk

Malai Paneer

Srikhand

Table Butter

Jeera Tak

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Cream

When milk fat is concentrated into a fraction of the original milk, that

portion is known as cream. Cream is a rich portion of milk fat.

Cream is the product of cow or buffalo milk or a combination thereof

which contains not less than 25 % milk fat.

The various types of cream are:

Table Cream

} containing 20 - 25 % milk fatLight Cream

Coffee Cream

Whipping Cream

} containing 30 - 40 % milk fatHeavy Cream

Plastic Cream containing 65 - 85 % milk fat

Katraj Dairy has been manufacturing plastic cream with 65 - 75 % milk fat.

Composition

Water 22 - 32 %Fat 65 - 75 %

Protein 1 - 1.2 %

Lactose 1.2 - 1.5 %

Ash 0.3 - 0.4 %

Total Solids 68 - 78 %

SNF 2.5 - 3.2 %

Packing Sizes

1000 Grams poly bag

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Ghee

Ghee is the pure clarified fat derived solely from milk or from desi

(cooking) butter or from cream to which no coloring matter is added.

Ghee is the clarified butter fat prepared chiefly from cow or buffalo

milk.

Ghee is used as a cooking or frying medium, in confectionary, for direct

consumption with rice chapattis etc.

Cow ghee is mainly used in indigenous pharmaceutical preparations

(Ayurveda).

ProcessMilk

Centrifugal separation

Cream

Ripened or unripe Ned

Heating up to 110 C

Ghee

Cooling

packing & storage (room temperature)

CompositionMilk Fat not less than 99.7%Moisture not more than 0.3 %

Free Fatty Acid (oleic) max 1.4 %

Packing Sizes500 gms poly pack

15 Kg tin

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Lassi

Lassi is a fermented Milk beverage popular in all parts of India. The

technology of lassi making is however confined to only households. Lassi

has a great potential in the Indian Market.

Process

Standardization of whole milk

Heating (85 C for 10 mins)

Cool at 35 - 37 C

Inoculation starter culture & mixing

Incubation at 37 C

when curd is set : addition of sugar in the form of syrup which has already been pastuerized

and cooled separately

smooth consistency of lassi is obtained by passing the mixture through a homogenizer

Pouch packing

Storage at refrigerator temperature

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Composition

Water 75 - 80 %


Fat 3 - 4 %

SNF 6 - 7 %

Protein 3 - 4 %

Lactose with sugar 12 - 15 %

Ash 0.4 - 0.6 %

Lactic acid Maximum: 0. 75 %

Packing Sizes

200 ml poly pack

Process

Std or Whole Milk

Heating (85oC for 10 mins)

Cooling (at 35 to 37oC)

Inoculation starter culture and mixture

Filling in mud pots (Matkha) with mixture for setting

Incubation at 37oC

Capping and refrigerating

store at refrigeration temperature

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Milk is an almost ideal food. It has high nutritive value. It supplies body

building proteins, bone forming minerals and health giving vitamins

and furnishes energy giving lactose and milk fat. Besides supplying

some essential fatty acids, it contains the above nutrients in an easily

digestible and assailable form. All these properties make milk animportant food for pregnant women, growing children, adolescents,

adults, invalids, convalescents and patients alike.

Milk may be defined as a whole, fresh, clean, lacteal secretion obtained

by the complete milking of one or more healthy Milk animals excluding

that obtained within 15 days before or 5 days after calving or such

periods as may be necessary to render the milk practically colostrums

free and containing the minimum prescribed percentage of milk fat and

milk-solids-not-fats.

Pasteurization: The term pasteurization refers to the process of heating

each & every particle of milk to at-least 63 C for 30 minutes, or 72 C

for 15 seconds in approved and properly operated equipment. After

pasteurization the milk is gradually cooled to 5 C or below.Homogenization: Homogenization refers to the process of forcing the milk through a

homogenizer with the object of sub dividing the fat globules.

Standards of different Milks

Class of Milk Minimum% M. Fat % SNF

Cow Milk 3.5 8.5

Standardized Milk 4.5 8.5

Toned Milk 3.0 8.5

Double Toned Milk 1.5 9.0

Skimmed Milk Less than 0.1 8.7

Full cremed Milk 6 9.0

Buffalo Milk 6 9

Katraj also deals in Bulk milk supply to customers purchasing minimum

3000 liters of milk and in multiples of 100 liters thereof

Malai Paneer

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Paneer refers to the milk solids obtained by the acid coagulation of boiledwhole milk & subsequent drainage of whey. The acids commonly used arecitric in both natural & chemical forms.

Traditionally paneer has been a variety of pressed channa, used mainly inpreparing cooked vegetable dishes like palak paneer, paneer butter masalaetc.

Process

Paneer refers to the milk solids obtained by the acid coagulation of boiledwhole milk & subsequent drainage of whey. The acid commonly used are

citric in both natural & chemical forms.

Traditionally paneer has been a variety of pressed channa, used mainly inpreparing cooked vegetable dishes like palak paneer, paneer butter masalaetc.

standardization of whole milk ( 4.5 to 6.0 % fat )

pasteurization ( 85 C for 10 mins )

cool at 70 - 75 C

coagulation with 1 % citric acid solution

whey draining with muslin cloth

moulding & pressing

cutting, packing and storage below 4 C

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Composition

Moisture 50-55 % (Not more than 70 %)

Total Solids 45- 50 % (Not less than 30 %)

Fat 26 - 28 %

(Not less than 50 % of dry matter)

Ph 6.0

Packing Sizes

200 gms poly bag

500 gms poly bag

1000 gms poly bag

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Shrikhand

Shrikhand is a semi-soft sweetish - sour whole milk product prepared

from lactic fermented curd. the curd (dahi) is partially strained through

a cloth to remove the whey and thus produce a solid mass called chakka(the basic ingredient for shrikhand). This chakka is mixed with the

required amount of sugar, cardamom, jaiphal etc. to yield shrikhand.

Process

standard buffalo milk ( 4.0 to 4.5 % fat )

pasteurization ( 72 C for 15 sec )

cool to 37 C

addition of lactic culture ( 1% )

incubation at 37 C for 8 - 10 hours

when acidity 0.7 - 0.8 % : placed in a muslin cloth bag & hung for the removal of whey for 8 - 10

hours

solid mass production called chakka

mixing chakka with sugar, cardamom, jaiphal etc.

packing and storage below 4 C

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Composition

Moisture Max: 42%

Fat 8.5% = dry basis

Lactic acid 1.4 %

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Jeera tak

Jeera Tak is also called chhas or mattha refers to desi buttermilk.

Process

standard buffalo milk ( 4.0 to 4.5 % fat )

pasteurization ( 71 C for 10 mins )

cool to 37 C

addition of lactic culture ( 1% )

incubation at 37 C for 8 - 10 hours

when acidity 0.7 - 0.8 % :Addition of water, sugar, salt and jeera

powder.

mixing of water, sugar, salt, jeera powder and dahi with agitator or

mixer.

Pouch packing

storage below 4 C

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Composition

Water 95 - 96 %


Fat Min: 1%

SNF 2.0 - 2.5 %

Protein 1 - 1.5 %

Lactose 1.2 - 1.5 %

Ash 0.4 %

Lactic Acid Max: 0.35 %

Packing Sizes

200 ml poly bag

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Rate card

(profile)

The products and prices displayed here are for information only and

are subject to change without prior notice. Please confirm the

product availability and applicable prices at the time of ordering.

Sr. No Details M.R.P. (Rs.)

1. Tonned Milk (1 ltr) 22.00

2. Tonned Milk (500 ml) 11.00

3. Tonned Milk (250 ml) 05.50

4. Tonned Milk (loose in cans) 19.75

5. Double Tonned Milk (1 ltr) 21.006. Double Toned Milk (500 ml) 10.50

7. Double Toned Milk (250 ml) 05.25

8. Double Toned Milk (loose in cans) 17.75

9. KATRAJ Slim Milk (1 ltr) 16.00

10. KATRAJ Slim Milk (500 ml) 08.00

11. KATRAJ Slim Milk (250 ml) 04.00

12. KATRAJ Gold (1 ltr) 26.00

13. KATRAJ Gold (500 ml) 13.00

14. KATRAJ Gold (loose in cans) 23.00

15. Standardized Milk (1 ltr) 24.0016. Standardized Milk (500 ml) 12.00

17. Standardized Milk (loose in cans) 21.75

18. Cow Cream -1 Kg 130.00

19. Cow Cream Loose (1 Kg) 120.00

20. Cow Butter (Loni) - (1kg) 155.00

21. Cow Ghee (500 ml) 90.00

22. Cow Ghee (200 ml) 38.0023. Cow Ghee Tin (15 Lit) 2600.00

24. Buffalo Ghee (500 ml) 100.00

25. Buffalo Ghee Tin (15 Lit) 2850.00

26. Buffalo Cream 1 Kg 140.00

27. Buffalo Cream Loose (1 Kg) 130.00

28. Paneer 1 Kg 120.00

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29. Paneer 500 gms 65.00

30. Paneer 200 gms 33.00

31. Shrikhand 500 gms cup 46.00



34. Shrikhand -Loose ( 1 Kg) 75.00

35. Amrakhand 500 gms cup 40.00



38. Amrakhand Loose ( 1 Kg) 76.00

39. Chakka 1 Kg 75.00

40. Chakka 500 gms 40.00

41. Chakka Loose ( 1 Kg) 67.00

42. Table Butter - 100 gms Packet 20.00

43. Table Butter - 100 gms (1 Kg) 200.00

44. Table Butter - 500 gms Packet 90.00

45. Table Butter - 500 gms (1 Kg) 180.00

46. Matka Dahi 200 gms 16.00

47. Matka Dahi 100 gms 10.00

48. Dahi Loose ( 1 Kg) 36.00

49. Flavored Milk 200 ml 09.00

50. Jeera Tak 200 ml 08.00

51. Lassi 200 ml 11.00

52. Pedha - (250 gm) 45.00

53. Pedha - (500 gm) 80.00

54. Pedha - (1 kg) 160.00

55. Khao -(500 gm) 80.00

56. Khao -(1 kg) 160.00

57. Khao -( loose -1 kg) 145.00

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(CHAPTER 5)

CONCLUSION AND

SUGGESTIONS

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CONCULSION

Katraj dairy milk company is well known as milk Product Company havingits plant just inside Pune. Since its establishment to this present day thecompany has grown by lips and bonds.The company takes optimum care of its workers in every possible wayswhich we observe amply.To start with workers are provided with shoes hand gloves etc.Along with subsidized food in the canteen.While it will be unfair to judge and compare its market standing with otherindustries of the same sector, however this study focuses on the production

procedure of this particular company also this study bring out manyinteresting facts and figures which are incredible and enlightening.

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Suggestion

Katraj dairy mainly produce milk products over the years it has proved itscreditability. Even the company is doing well in term of overall sales thefollowing suggestion can be implemented to improve their service.

The company should have tie ups with some of the branches.

As a company with a turnover of (33 million $) it should employ more

workers.

As milk products is related with the health of people the plant cleanness is

an important area which a lot is remained to be achieved.

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(CHAPTER 6)

BIBLIOGRAPHY

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WWW.KATRAJDAIRY.COMWWW.GOOGLE.COM

WWW.WIKIPEDIA.COM
http://www.katrajdairy.com/http://www.google.com/http://www.wikipedia.com/http://www.katrajdairy.com/http://www.google.com/http://www.wikipedia.com/

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