Notes on Amul Dairy Process

Introduction

• Amul: The largest producer of milk in the world.
• History: Serving fresh and healthy milk since 1946.
• Contribution: Dr. Vargas Kurien, celebrated as the "Milkman of India".
• National Milk Day: Celebrated on November 26th in his memory.

Importance of Milk

• Milk is a staple in Indian diets—essential for sweet dishes and beverages.
• Nutritional Value of Milk:
  • Calcium (29%)
  • Phosphorus (23%)
  • Protein (16%)
• Essential for bone density and strength.

Supply Chain and Cooperative Model

• Amul has over 3.6 million milk producing members.
• Provides veterinary services and technology adoption to farmers.
• Milk collected daily from cooperative societies:
  • Women and society-trained staff collect milk samples.
  • Checks for quality parameters before collection.
• Direct linkage between producers and consumers, eliminating middlemen.

Milk Processing Steps

1. Collection and Transport:
   • Chilled milk collected in insulated tankers.
   • Quality checks at the milk-receiving dock.
2. Pre-treatment & Pasteurization:
   • Milk filtered for impurities.
   • Heated to 72.5°C for 15 seconds to kill bacteria.
3. Homogenization:
   • Reduces fat molecule size to prevent cream separation.
4. Packing:
   • Various pack sizes: 200ml, 500ml, 1 liter, and 6 liters.
   • High automation in packing machines.
   • Example: Amul Gold - minimum 6% fat, 9% SNF.

Advanced Packing Technology

• Robotic Systems: First-of-its-kind robotic packing in India.
• Aseptic Packing: Uses Tetra Pak technology, can store milk for up to 6 months without refrigeration.
• Process of Aseptic Packing:
  • Quick heating to 135-140°C followed by rapid cooling.
  • Multi-layer packing material for protection and durability.

Quality Assurance

• Regular testing for leak-proof and joint strength.
• Automated clean-in-place (CIP) system to maintain hygiene standards.

Innovations and New Products

• Lactose-Free Milk: For those with lactose intolerance.
• Cal C Plus Milk: Fortified milk with additional calcium.
• Amul Creamer: Suitable for consumers; pack it in sterilized cups.

Logistics & Delivery

• Automatic storage and retrieval systems (ASRS) manage storage.
• Delivery trucks designed to maintain temperature.
• Regular twice-a-day deliveries to various cities.

Conclusion

• Amul’s Mission: Providing fresh, high-quality milk to millions across India.
• Role in Society: Positive socio-economic impact on rural communities.