Detailed Project Report (DPR) on Skimmed Milk Powder and Butter from Cow Milk (Capacity: 37800 kg per day)

SKIMMED MILK POWDER AND BUTTER FROM COW MILK

[EIRI/EDPR/4463] 

Milk Powder is the milk that has been dried or desiccated. This is usually done by heating the milk. The final product contains less than three percent water. Milk powder can be prepared from whole milk. Milk from which fat has been partially removed, or from skim milk.

Shimmed Milk Powder is a product obtained by the removal of water from skimmed milk by heat or other suitable means to produce a solid containing a solid containing 5% or less moisture.

There are a number of advantages in converting milk into milk powder. Milk contains Eighty-seven percent water and because of this it gets spoilt quickly. It also needs special and bulky containers for transport. On the other hand, milk-powder takes up only one-eighth of the space of the original milk. Besides, milk in powder form can keep for a long period as much as six to eight months under tropical conditions.

There are three main types of plant for producing milk powder or dried milk.

i) Roller driers

ii) Spray driers

iii) Vacuum roller driers.

Most of the powder in Great Britain is produced by roller driers but there is an increasing amount made by the spray process, vacuum roller, plants are not used in Great Britain. Rollers and spray dried powders differ considerably in their appearance and properties.

Roller powder is creamy in colour, granular "crystalline" in appearance and has characteristic tallowy or "oxidised-fat" odour.

Spray powder is a fine white powder which reconstitutes more easily than roller powder on account of the milder heat treatment and smaller size of particle. However, roller powders are of better bacteriological quality as the milk receives a more intensive heating.

The dairy industry, covering the production, processing and distribution of milk and milk products, is unique in its important as it is concerned with valuable food stuffs, universally consumed by men. Milk is the fresh lacteal secretion of milk animals naturally intended for the nourishment of the offspring but exploited as an article of food by the human race. It is essentially an emulsion in a continuous phase. The disperse phase consists of fat globules of varying diameter from 0.1/u  to 10/u (2.5-3.0/u). The number of globules varies from 2.5x109 to 25x5x109 per c.c. the globules are surrounded by layers of protein phosphatides and probably also carotent and cholesterol which prevents them from coalescing together to larger globules. The milk when they get globules coalesce to form butter. Milk a fat or butter consists of glycerides mainly of butyrides caproci acids which posse’s characteristic odours.

Ghee refers to the fat concentrate obtained mainly from butter or cream by the removal of practically all the water and solids not fat content. The terms milk fat, anhydrous milk fat, dry butter fat are told as ghee. But the raw material for its preparation is cream.

COST ESTIMATION

Plant Capacity            37,800 KG/Day  

Land & Building (10,000 sq.mt.)    Rs. 6.10 Cr    

Plant & Machinery                    Rs. 21.00 Cr 

Working Capital for 1 Month    Rs. 34.32 Cr 

Total Capital Investment          Rs. 61.78 Cr 

Rate of Return                          40%

Break Even Point                      37%

CONTENTS

INTRODUCTION

MILK SELECTION

TABLE

COMPOSITION OF MILKS OF COWS, BUFFALOES, GOATS & SHEEP

COMPOSITION OF DRY MILK POWDER

COMPOSITION OF DRY MILK & MILK PRODUCT

PROPERTY OF MILK POWDER

1. SOLUBILITY:

2. COLOUR:

3. HYDROSCOPIC PROPERTIES:

4. TESTS:

COMPOSITION OF MILK-POWDER

THE AVERAGE COMPOSITION OF MILK POWDERS:-

PROPERTIES OF GHEE

PHYSICAL PROPERTIES

CHEMICAL PROPERTIES

USES AND APPLICATION OF SKIM-MILK POWDER

CONFECTIONERY:

BAKERY:

ICE CREAMS:

HEALTH BENEFITS

USES OF GHEE

B.I.S SPECIFICATION

TABLE 1 REQUIREMENT FOR MILK POWDER

INDIA SKIMMED MILK POWDER MARKET

MARKET SCENARIO OF SKIMMED MILK POWDER

WORLD’S LARGEST SMP IMPORTERS

WORLD’S LARGEST SMP EXPORTERS

USA

INFRASTRUCTURE

PROMINENT ENTITIES

INVESTMENTS AND STANDARDS

PRICE REGULATIONS

NEW ZEALAND

DAIRY INDUSTRY

DAIRY GENETICS

MANUFACTURING

INDIAN EXPORT OF SMP

INCREASED PRODUCTION

STRATEGY TO PROMOTE INDIAN SMP

USA & EU

FORECAST

CHINA TRADE TARIFFS

INDONESIA AND EU

INTERNATIONAL TRADE IN SELECTED MILK PRODUCS

BUTTER

FIGURE: BUTTER EXPORTS AND FAO BUTTER PRICE INDEX

SKIM MILK POWDER

FIGURE: UNITED STATES SMP EXPORTS

WHOLE MILK POWDER

APPENDIX TABLES STATISTICS

PROCESS OF MANUFACTURE

ROLLER DRYING:-

MILK POWDER PRODUCTION PROCESS

SEPARATION/STANDARDIZATION

PREHEATING

EVAPORATION

SPRAY DRYING

PACKAGING AND STORAGE

PROCESS DESCRIPTION OF MILK POWDER

MILK POWDER PRODUCTION

MILK CONCENTRATE ATOMIZATION

MILK CONCENTRATE VISCOSITY

MILK POWDER PRESSURE NOZZLE

CONE ANGLE

MILK POWDER SWIRL CHAMBER

MILK POWDER HIGH PRESSURE NOZZLE ORIFICE SIZE

MILK POWDER PRODUCTION CONCENTRATE FLOW RATE

MILK POWDER PRODUCTION HIGH PRESSURE NOZZLE PRESSURE

CENTRIFUGAL ATOMISER

INLET TEMPERATURE

POWDER IGNITION TEMPERATURE

OUTLET TEMPERATURE AND POWDER MOISTURE

PROCESS FLOW DIAGRAM

MILK POWDER SYSTEM

CHANGES OF STATE OF THE DRYING DROPLETS

DRYING STAGES

DRYING PROCESS

CONCENTRATION GRADIENTS

AROMA RETENTION

TECHNICAL DETAILS OF MILK POWDER PRODUCTION

MANUFACTURING PROCESS OF GHEE

PROCESS FLOWSHEET FOR MANUFACTURE OF MILK POWDER AND GHEE

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

SUPPLIERS OF RAW MATERIALS

ADDRESSES OF PLANT AND MACHINERY SUPPLIERS

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)