A review on mechanization of traditional dairy products

Gopika Talwar* and Sandeeppal Kaur Brar**

*Assistant Professor( Dairy Engineering), College of Dairy Science and Technology, GADVASU, Ludhiana , Punjab

** Junior Research Fellow, College of Dairy Science and Technology, GADVASU, Ludhiana, Punjab

ABSTRACT
India is the largest milk producing nation in the world. Milk is perishable in nature, thus it can not be stored for a very long
period. In order to preserve it, more than half of milk produced in India is converted into a variety of traditional value added
milk products which played a significant role in the Indian economy. Traditional milk products have a distinct advantage of
being value added products, mass appeal, give high profit margins and have high export potential. Indian traditional dairy
products are largely classified into 5 broad categories i.e. Heat desiccated products, acid coagulated, cultured or fermented,
fat rich and milk based deserts . Increasing demand for these products in India as well as global market present a great
opportunity for the organized dairies in the country to modernize and scale-up the production. There has been significant
development and mechanization in dairy sector in past few years. It has transformed various processes for dairy products
from traditional energy and labour intensive processes to mechanized processes where human interference is minimized. In
this article various researches and adoptions done for mechanization of various dairy processes is reviewed. This will help in
knowing products where mechanization has taken place and will help researchers to target where mechanization is further
required and also help entrepreneurs to upgrade themselves from traditional system to available mechanized system.

Keywords: Traditional dairy products, mechanization, khoa, packaging,paneer

1. INTRODUCTION

In Indian economy, there has been significant development in dairy sector in past decade. Today,
India is the largest producer of the milk and value added milk products in the world accounting for more
than 16% of worlds total milk production. The total milk production in India is over 132 million tonnes.
Milk production increased steady from 116.4 million tonnes in 2009-10 to 132.43 million tonnes in 2012-
13 (Anonymous, 2011-2012). Although 46 per cent of the milk produced in the country is consumed as
liquid milk, the increase in consumption can be stimulated. Milk plays an important role in the national
diet as it is consumed in liquid form as well as value added products like Dahi, Paneer, Butter, and sweets.
Also milk can be preserved for longer period by converting significant proportion of milk into a wide
variety of dairy delicacies. It is estimated that 50 to 55 per cent of the milk produced in India is converted
into a variety of traditional milk products, using processes such as coagulation (heat and/or acid),
desiccation and fermentation. The market for Indian milk products is estimated to be 10 billion US dollar
([Link]). This fact underlines the significance of Indian milk products in the national economy.
Over the millennia, the processes and technologies for manufacture of value added dairy products have
undergone a change. It has transformed from traditional energy and labour intensive processes to
mechanized processes where human interference is reduced. Mechanization provides many advantages like
uniform quality and less use of labour, less spoilage etc. Some of the technologies and mechanized
processes have been adopted by organized or unorganized sector. It is important to review the traditional
processes in comparison to new processes to study the impact of mechanization in different categories of
dairy product manufacture. Recently a few organised dairy sectors have made attempts to develop batch,
semi continuous, and continuous equipments for production of traditional dairy products on a commercial
scale. While many new innovations have taken place recently to modernize this sector, but have not
percolated to the actual users. Hence, it is necessary to look into short, medium and long term strategies to
develop core technological strengths for envisioning a developed indigenous dairy products sector. To
judge the extent of mechanization in dairy sector it is important to know the different processes and
technologies that have come up in dairy sector.

2. RECENT ADVANCEMENTS IN MECHANIZED MANUFACTURING OF

TRADITIONAL DAIRY PRODUCTS
The making of traditional dairy products has essentially been a cottage scale enterprise. Although
information available on these products is inadequate, an effort has been made to focus on their
technologies, including their preparation, physic-chemical attributes, shelf life behaviour, packaging and
the like. In this section, the technological aspects of wide range of Indian dairy products that are largely
followed or are under development, are presented under five broad categories, listed below:

2.1. Heat desiccated milk based products

2.2. Heat and acid coagulated products
2.3. Cultured/Fermented products
2.4. Fat rich products
2.5. Milk based puddings/Desserts
2.1. HEAT DESICCATED MILK BASED PRODUCTS:
Heat desiccated milk products are those products which are prepared by heat desiccation of milk
and by subsequently adding sugar in to it. Khoa, an intermediate base for a wide range of sweets such as
Gulabjamun, Burfi, Peda, Kalakand, Rabri, Kulfi etc. is a good example of heat desiccated product. The
heat processing and accompany reduction in water activity result in substantial destruction of pathogenic
and spoilage micro organisms as well as inactivation of enzymes. Besides, desirable heat induced chemical
interactions among milk constituents result in reduction of redox potential and water activity which extend
the product shelf life. Besides these desirable flavours, texture and overall acceptability of the product is
enhanced by heat processing. During desiccation whey proteins are almost fully denatured from colloidal
state of non-dispersible state. The factors that influence the heat coagulation are temperature and time of
holding, concentration of casein, acidity of milk, salt balance and precise heat treatment. The colour of
milk changes from light to a more intense shade of the colour due to denaturation and coagulation of
protein. Due to vigorous agitation of milk at high temperature the fat globules are appreciably sub-divided.
Almost half of the globular fat is released as free fat-the extent of which depends upon the type and fat
content of milk and manufacturing process. Usually 44.8 to 62.8 % of fat appears as free fat in khoa.
2.1.1 KHOA
 The traditional method for preparing khoa utilizes simple utensils and direct smoke-free fire for
desiccation. Typically, 4 to 6 litre lots of milk are taken in shallow iron/mild steel pan and simmered over
direct non-smoky fire with constant and vigorous stirring and occasional scrapping of the heating surface
to avoid building of scale/scorching. After some time of rapid evaporation, when concentration of about
2.5 to 3 times has been attained, coagulated particles are brought together with the stirrer and compacted as
a semi-solid mass.
As heating continuous further with constant agitation and scrapping of the heating surface, free fat
oozes out. From this stage, subsequent heating has a pronounced effect on the development of typical khoa
flavour and texture. Since colour tends to change rapidly at this stage, heating is slowed down. Gradually,
the solid mass tends to leave the heated surface cleanly, and a pat is formed. The end product is then
removed from the pan, spread uniformly over trays and allowed to cool under atmospheric conditions.

This method is labour and energy intensive and the end product varies in quality from batch to
batch. Further, the microbiological quality of the product is susceptible to environmental influences due to
desiccation under open atmospheric conditions. The need was felt to develop a design for mechanised
production and packaging of khoa. Several researches have been made to mechanize the process for large
scale manufacture of khoa in the commercial sector. The first attempt to develop prototype or mechanized
production of khoa was made in the 1960’s at the National Dairy Research Institute (NDRI), Karnal.
A semi continuous khoa making machine was first developed by Banerjee et al ;1968 and its
subsequent modification was done by De and Singh (1970). The equipment comprised of a scraped surface
heat exchanger (for pre-concentration of milk) and two open semi jacketed steamed pan with mechanical
scraper agitators (for final concentration of milk). This equipment was quite suitable to replace traditional
appliances for cottage scale operation but was too bulky and the product was lacking in organoleptic
quality.
Sawhney et al ;1980 followed by More ,1987 designed batch type semi-continuous mechanized
scrap surface heat exchanger by providing steam jacketed pan and scraper assembly. This was good
attempt for production of khoa under rural conditions but found unsuitable on commercial scale.
For efficient use of thermal energy and less heat, Agarwala et al ; 1987 developed a mechanized
conical vat for preparation of khoa. A prototype of khoa making machine consisted of a horizontal cylinder
of mild steel having a steam jacket on the lower half side was developed (Christie and Shah, 1988).
Inspired by the performance of this prototype machine, another batch type machine of stainless steel with
power drive was developed by Christie and Shah, 1990.
The use of horizontal thin film SSHE was reported for continuous khoa production (Abichandani
and Sarma, 1985). A correlation was developed for power requirement to drive the rotor for a straight
sided thin film SSHE by taking water as a working fluid (Abichandani and Sarma, 1988). Thin film SSHE
application was extended for concentration of milk to high solids and its suitability for continuous khoa
production was confirmed (Dodeja et al ; 1990). The performance of thin film SSHE was evaluated at
different rotor speeds and steam temperatures for continuous manufacture of khoa (Dodeja et al ; 1990).
National Dairy Development Board has developed an inclined scraped surface heat exchanger (ISSHE)
was developed to manufacture khoa continuously (Punjrath et al ; 1990).
The heat exchanger comprises of inner cylinder, rotor drive and outer steam jacket. In this system the
scraper repeats the process of moving coagulated particles from heat transfer surface and mixing them
back to pool of liquid. The angle of inclination of ISSHE permits the formation of pool of boiling milk
critical for formation of khoa.
Rajorhia et al 1991 compared the quality of khoa prepared viz; ISSHE, convap-contherm conical vat and
roller drier with regards to physic-chemical characteristic, sensory properties, rheological properties and
operational features. It was concluded that among the selected systems inclined surface heat exchanger
(ISSHE) proved to be the most appropriate for continuous manufacturing of khoa.
The effects of various parameters on evaporation of water, concentration of milk, and dehydration of
cream in straight sided horizontal thin film SSHE was reported (Abchandani and Sarma, 1991). A thin film
SSHE system of mild steel for continuous manufacturing of khoa by arranging two SSHE in a cascade
fashion was developed (Dodeja et al ; 1992). Later on, the quality of khoa obtained from this machine was
attempted to improve by adding a third stage with modified rotor blade assembly (Kumar et al ; 2009). A
continuous khoa making unit of mild steel was developed by arranging three identical SSHE one over
another to control the product flow under gravity (Bhadania et al ; 2005).
In Industrial production of khoa, energy conservation is an important consideration. Concentration
of milk in an open pan is energy intensive and uniformly smooth khoa is required to impart the desirable
texture to the finished product as it emerges from the SSHE. Keeping in view these aspects, the first
attempt to apply pressure driven membrane separation process of reverse osmosis has been successfully
tried by Pal and Cheryan, 1987. The utilization of solar energy in dehydration of milk for the manufacture
of khoa was attempted, and reported that solar method of dehydration results in less evaporation of water
from milk (Dande et al ; 2011). A 3-stage SSHE for manufacture of khoa was developed (Dodeja and
Deep, 2012) and the quality of khoa manufactured from SSHE was claimed to be comparable with the
market samples.
2.1.2 KHOA BASED SWEETS
Successful attempts have also been made to mechanize the process for manufacturing of khoa
based sweets.
A mechanized process for commercial production of burfi was successfully developed by (Palit
and Pal, 1998) at NDRI. The process involved the continuous khoa making from SSHE/TSSHE followed
by kneading and heating khoa sugar mixture in Stephen kettle for uniform blending. Later on there was
development of a three stage burfi making system for the continuous manufacturing of burfi but industrial
trials indicated accumulation of product inside SSHE causing non-uniform flow due to improper expelling
action. In order to overcome the drawback of existing rotor blade assembly a new rotor blade assembly
was fabricated by providing a combination of flat blades and skewed blades (Kunju and Dodeja, 2004).
Better quality and minimum accumulation of product was obtained at maximum rpm and maximum
skewed blade angle.
[Link] PEDA
 Peda is an indigenous milk product, prepared by mixing khoa with copious quantities of sugar.
Patel (1986) reported that peda can be prepared with 5 liters milk taken in a pan as a batch and by adding
450 g of sugar to boiling milk and subsequently following traditional method. Many workers have studied
different methods to modify the process of peda making. Reddy (1985) followed by Mane (1994)
developed a process for preparation of plain peda using skim milk powder (SMP). Deewani and
Jayapraksha (2002) made use of whey protein concentrate (WPC) in preparation of peda and found that
sensory characteristics can be enhanced by increasing level of WPC up to 40%. Londha (2006) has also
prepared peda by addition of boora i.e. sifted sugar (30% on khoa basis) after khoa was prepared from
buffalo milk (5.9% milk fat). In plain peda making process, prolonged heating of milk leads to severe
browning and loss of nutritional quality. To overcome this problem, reverse osmosis technology was
adopted by Dewani and Jayaprakash (2006). For mechanized production of peda, some plants have
recently undertaken use of mechanized equipment and Rheon extruder. However Patel et al (2006)
reported that the pea manufactured using traditional method was superior in chemical and sensory quality
than those manufactured using mechanized methods.
[Link] RABRI
Rabri is a partially concentrated and sweetened milk product containing several layers of clotted
cream. Based on market survey, Gayan and Pal (1991b) has standardized method of manufacturing for
rabri. A mechanized method of manufacturing of rabri employing SSHE for concentration of milk, and
addition of shredded channa/ paneer in place of clotted cream (added in traditional method) has also been
developed by Gayan and Pal (1991b). For large scale production of rabri, Pal et al ;2005 successfully
developed a technology using thin film scraped surface heat exchanger (TSSHE).
[Link] BASUNDI

Basundi is a heat desiccated, thickened milk dessert, prepared by repetitive boiling of sugared milk. Patel ,
1999 carried out systematic studies to develop standardized procedure for making basundi on commercial
scale, which was later recommended by Patel and Upadhaya ,2003. A mechanized prototype of scrapped
surface heat exchanger was designed and developed to suit the standardized process of basundi making
(Rajasekhar et al ; 2003). In order to evaluate the performance of three different shapes of SSHE viz.
Cylindrical type, conical type and Karahi type, overall heat transfer coefficient (U value) was taken in to
consideration. The results showed that Karahi type SSHE could give higher U value.
[Link] GULABJAMUN
Gulabjamun are being manufactured commercially using khoa portioning and ball forming
machines followed by deep fat frying and sugar syrup soaking lines. (Banerjee, 1997). In new technology
developed for industrial production of gulabjamun using an assembly-line system is in use at Sugam Dairy
Vadodara. Khoa with 30-40% moisture is mixed in a planetary mixer with about 19-20% maida and 0.5%
baking powder. In a portioning machine dough is cut into 8 gm weights and conveyed to ball forming
machine. The balls are carried to frying vat containing vegetable oil at temperature of 140 oC. After proper
cooking, the balls are shifted to sugar syrup tank containing syrup (62.5% solution). The gulab jamun balls
are packaged in plastic container along with an appropriate amount of hot syrup. Then the plastic cups are
heat sealed with lids and stored under refrigerated conditions. Canned gulabjamuns are stoed at room
temperature.
2.2 HEAT AND ACID COAGULATED
Paneer and Channa are two prominent traditional heat and acid coagulated products. Paneer the
indigenous variety of cheese is prepared by acid coagulation of heated milk. The phenomenon of
coagulation involves physical and chemical changes in casein brought about by heat and acid treatments.
Channa, a base product for a large variety of Indian delicacies is also heat acid coagulated product. it
differs from Paneer as no pressure is applied to drain whey and its pH is slightly higher.
2.2.1 PANEER
In the traditional production process of Paneer, buffalo milk (6% fat, 9% SNF) is boiled in a
vessel. To coagulate the milk while still hot, a suitable coagulant (lime/alum/citric acid) is added, with
slow stirring. Formation of clear whey is indicative of complete coagulation. Stirring is stopped, as the
coagulum tends to coalesce. After the formation of large lumps is complete, contents of the vessel are
poured over a muslin cloth to separate the coagulum from whey. The coagulum so obtained is lightly
pressed to facilitate formation of paneer blocks of suitable size, followed by their immersion in chilled
water to impart them distinctive texture.

Paneer manufacture has traditionally been an intensely manual operation, requiring a large labour
force and using equipment that could be used for a number of other processes. Paneer mechanization
describes the use of machinery to replace manual operations in traditional small-scale manufacture and the
development of equipment that was targeted at specific tasks. A few studies which have been done on
manufacturing of paneer are discussed under below:

To develop domestic gadget for paneer making, studies on whey drainage and matting of curd
were carried out using a test cell (Mudgal et al ; 1995a & b). Based on the findings a batch unit for
handling milk up to two liter was designed and developed at NDRI, Karnal (Bikram, 1995). For continuous
paneer making, a twin-flanged apron conveyor cum filtering system was designed at NDRI to manufacture
80 kg paneer per hour for obtaining the desired moisture content and texture attributes (Agarwala et al ;
2001). Das and Das (2009) used an impact type device for manufacture of paneer. For the pressing, curd
was kept in cages made from a special type of screen and the cages were subjected to impact forces for
preparation of paneer.

The production of good quality paneer using ultrafiltration (UF) has been reported by Sachdeva et
al ;1993. The process offer advantages like mechanization, uniform quality, improve shelf life, increased
yield and nutritionally better product. In another approach, a fully sterilization product has been developed
which gives a long shelf life paneer like product (Rao, 1996). Gupta and Pal (1995) observed that paneer
made from milk concentrated by reverse osmosis to 1.5x (25% TS) and 2x (33% TS) resulted in higher
yield by 2–3% on original milk amount basis compared to control without affecting its sensory properties.
Pal et al. (2002) conducted a study in which they concentrated cow milk to about 1.5 and 2.0 folds using
NF membrane system at 50 °C and found that the NF reduced the salt content of cow milk up to 74% in
1.5 fold concentrations without affecting other major constituents. Kanawjia and Rizvi (2003) used
microfiltration to develop paneer from skim milk concentrate utilizing three fat sources viz. butter oil,
cooking butter and plastic cream which were incorporated into skim milk retentate using homogenization.

2.2.2 CHEESE
Cheese is an analogous product to paneer and made from whole milk, skim milk, cream or their
mixture. Some cheeses are made from whey, whey cream or whey milk mixtures. According to the Food
and Agricultural Organization of the United Nations, over 20 million metric tons of cheeses were produced
worldwide in 2011. In total fewer than 25 varieties are popular in the world. The varieties may be grouped
or classified into types according to criteria such as length of ageing, texture, methods of making, fat
content, animal milk, country or region of origin, moisture content, presence of mold etc.—with these
criteria either being used singly or in combination but with no single method being universally used
(Ensrud, 1981). Depending upon above criteria, a list of classification of cheese is given in Table. (Anon
2011)

Table: Classification of cheese

Criteria Types of cheese Example

Age Fresh Cottage cheese, Cream cheese etc.
whey Italian cheese, Greek cheese etc.
stretched curd Mozzarella cheese
Moisture content or Semi soft Domiati cheese
firmness
Medium hard Swiss-style cheese like Emmental, Gouda,
Edam, Jarlsberg and Cantal etc.
Semi hard or hard Cheddar cheese, Edam, Gouda, Parmesan and
Pecorino Romano etc.
Fat content Cow’s milk, buffalo milk, Camembert cheese, Mozarella cheese, Channa
goat milk and sheep milk cheese, Cream cheese, Domiati cheese, Swiss
cheese etc.
Presence of mold Soft-ripened or Bloomy rind Brie, Camembert, Fromage D'Affinois etc.
Washed-rind Limburger and Appenzeller
Smeared ripened Munster and Port Salut
Blue Roquefort, Gorgonzola, and Stilton
Others Brined Feta, Halloumi, Sirene and Telemea etc.
Smoked Raclette, Garroxta etc.
 Many of the fundamental developments occurred from 1960 to 1970 and were reviewed by several
researchers. Investment in mechanized systems, including vats and mechanical curd-handling equipment,
has been extensive both in medium-sized and large plants as discussed below:

A fully mechanized new method for the manufacture of Cheddar cheese, based on rapid drainage
of curds in a special rotary drum, formation of large curd block, pressed hydraulically in the absence of
surface whey, and automatic milling, salting, and hooping,was first developed by McCadam and Leber
(1958). Janzen, 1964 has designed a mechanized prototype comprised of blue cheese draining and
hooping. The process involved sprinkling of mold powder on to the curd as it emerges from draining
cylinder followed by uniform distribution of mold within the hooped curd and addition of some salt at the
hooping stage appears feasible. The quality of the mechanically hooped Blue cheese (flavor, body and
texture, and mold distribution) so obtained were found to be satisfactory.

2.2.3 CHANNA
In traditional production of Channa, a small portion of boiled milk is transferred to a smaller
coagulating vessel. The required amount of coagulant (usually the previous day sour Channa whey) is
added to the hot milk and blended till the coagulation is complete. The vessel contents are then poured
over a piece of clean muslin cloth held over another vessel in which the whey gets collected. The
coagulation process is repeated till all the milk is converted into Channa. The muslin cloth containing the
curd mass is hung to further drain out whey and to cool the Channa simultaneously.
To overcome the problems of small scale, attempts have been made to mechanize Channa
production. The first prototype of continuous Channa making machine of capacity 40Kg Channa per hour
was developed at NDRI, involving tubular heat exchanger acid injector, hold and strainer (Aneja, 1977).
IIT, Kharagpur has used similar principle and obtained a patent on the mechanized production of Channa.
The process involves indirect heating of milk in a tubular heat exchanger to 95°C, cooling to 70°C,
continuous coagulation with hot citric acid (70°C), in a vertical tube, holding milk-acid mixture to permit
complete coagulation, separation of whey in a continuous flow employing double wall basket centrifuge
and chilling to 4°C, by directly spraying chilled water on the layer of Channa (Singh, 1994).

Some innovations in manufacturing process of Channa such as tray, spray and roller drying
(Tewari and De, 1976), use of concentrated and dried whole milk after reconstituting it up to 15 % TSS
(Kawal, 1979; Singh, 1991), continuous dewatering of channa coaglum by application of Transverse Jet
Mixer reactor (Sinha and Aggarwala, 2002), application of ultra filtration (Sharma and Reuter, 1991;
Kumar et al, 2005), use of herbal coagulants i.e. papaya and ginger extract (Singh et al ; 2005) have also
been made to produce good quality Channa.

2.2.4 CHANNA BASED SWEETS

Because of limited shelf life of Channa lasting only few hours and shortage of milk during lean
season, traders have to face many challenges. To overcome such problems, Singh (1991) standardized a
method for preparation of good quality Rasogolla using dried milk. Traditionally, Channa balls are
manually made working between palms. Kumar et al ;1997 designed a screw conveyor for kneading of
Channa and a cutter provided at the exit split the Channa in to lumps of 10g each. The lumps are made to
fall on a spinning disc and stationery disc above, which converts lumps into round balls. Das (2000)
developed a ball-forming device along with continuous cooker to mechanize the process of Rasogolla
making. Another machine has been developed which can do the dual job of Channa kneading and ball
making in continuous manner (Choudhary, 2002). Karunanithy et al ;2007 has also developed a Channa
kneader and ball former device and its performance was evaluated in terms of spherecity.
Technology for production of Rasogolla mix has been standardized by Pal et al (1993). Rasogolla
prepared from buffalo milk is usually hard and lacks sponginess, as well as desired body and texture.
Ramathilagam and Subramaniam (2005) investigated the suitability of buffalo milk for preparation of
Rasogolla, by carrying out certain modification in buffalo milk. Jayaprakash (2003) developed a
technology for production of sugar free Rasogolla using different artificial sweeteners.
Kumar (1998) developed a single screw vented extruder for continuous production of Sandesh. It
is claimed that about 80 % Channa produced in Kolkata is converted in to Sandesh (Aneja et al, 2002).
Kumar and Das (2003) optimised the processing parameters for the mechanized production of Sandesh.
Tewari et al (1991) took an initiative for manufacturing of Channa based table spread. A low fat
sweet dairy spread was developed by Babubhai (1999) keeping Channa and SMP as a major source of
protein. Reddy et al (2003) standardized another protein enriched table spread using Channa as a base
along with butter.
2.3 CULTURED/FERMENTED PRODUCTS
Dahi, Yogurt, Mishti dahi, Chakka, Shrikhand and Lassi are fermented milk products. However
they differ considerably in terms of cultures used and their bouquet and flavour profiles. The Bureau of
Indian Standards (BIS) specifications for fermented dairy products are based on the type of culture used in
their preparation. The culture is a soul of the product as it imparts distinctive smell and flavour profile to
the product. The detailed description and the recent technological advancements which have been taken
place in manufacturing of cultured/fermented products are discusses under below:
2.3.1 DAHI AND YOGURT
Dahi is an indigenous dairy product which is produced by lactic acid fermentation of milk. During
fermentation of milk, a lactic acid bacterium (culture) hydrolyses the lactose in to lactic acid as a major
product, which contributes to the more than 90% of acidity to dahi.
Like dahi, yogurt is a semi solid fermented product made from standardized milk mix by the activity of
symbiotic blend of streptococcus thermophilus and lactobacillus delbrueckii subsp. balgaricus cultures.
Traditionally dahi is prepared at small scale, either in the confectionery shop or in the household.
Milk is first boiled and then cooled to room temperature. Inoculation is done with 0.5 to 1.0 percent starter
(previous day’s dahi or butter milk) followed by incubation for setting for about overnight.

Cup Thermo- fill and Sealing Machine is now-a-days most widely used for the packaging of dahi.
Thermoforming of cups from the plastic film, filling of product and sealing of lids take place in continuous
sequence of operation. The machine has a feed hopper, filling pumps, filling nozzles and stirrer. A major
advantage of this machine is cutting down the cost of cups by 50%, since the cup is thermoformed and lid
is punched right on the machine itself.
2.3.2 CHAKKA & SHRIKHAND
Chakka is white pale yellow semi-solid product of good texture and uniform consistency
obtained by draining off the whey from dahi/yoghurt obtained by lactic fermentation of milk. It is
main ingredient for the manufacturing of shrikhand. Shrikhand an acid coagulated indigenous and
sweetish sour, fermented milk product. It is prepared by blending sugar, flaour color and spices to
chakka. It is popular delicacy in south-west parts of India, mainly Gujarat, Maharashtra and parts of
Karnataka. Although largely produced on small scale adopting age old traditional methods, with
growing demand, shrikhand is now commercially manufactured in organized dairy sector.
Aneja et al (1977) made successful attempts to develop an industrial process for the
manufacturing of shrikhand with a view of overcome limitations of traditional method of
preparation.
The first modern plant for manufacturing of shrikhand was established at Baroda District.
Co-operative Milk Producers Union Ltd. (Sugam Unit) in Gujarat in 1980. Since then, it has been
producing and marketing shrikhand under the brand name “SUGAM” & “AMUL” (Aneja et al ;
2002).
Aneja and Vyas (1983) developed a fully mechanized/continuous process for industrial
production of shrikhand. In this process chakka was prepared by separating the whey from skim
milk dahi employing 28” diameter basked centrifuge at 1100 rpm. The resultant chakka, sugar &
plastic cream are then mixed in a planetary mixer.
Increasing demand for these products present a great opportunity for the organized dairies in
the country to modernize and scale-up the production. A GCMMF-TCS Survey report has given
projected demand of Ghee, Paneer, Shrikhand, Rasogolla, and Gulabjamun to be 200, 16, 5.7, 6 and
5.9 thousand metric tones by year 2009 (Misra, 2000). Therefore, the expanding business prospects
provided by these products and their accompanying value-addition call for a thorough study of this
sector. There is a need to look into various issues and accordingly re-evaluate and re-engineer
ourselves to modernize traditional dairy products sector.
2.3.3 LASSI
Lassi scientifically is defined as a fermented milk beverage obtained after the growth of
selected culture, usually lactic acid streptococci, in heat treated or partially whole milk followed by
sweetening with sugar. It is prepared by breaking the curd into fine particles by agitation, addition
of sugar water and optionally flavour. By-product obtained in the preparation of desi butter from
dahi by indigenous method is also known as lassi. There has been no advancement in
mechanization for Lassi manufacturing but packaging sector used Form-Fill and Seal Machine(FFS)
for packaging of lassi in 60-80 micros LLDPE co-extruded pillow type pouches. Its operation is
similar to that of ghee pouch FFs machine. Other than theses packaging machinery research has
been done in technology advancement in lassi making and its shelf life extension.
 Lassi using buttermilk and soybean was made by Deka et al (1984). The blanched soybean
cotyledons were ground with buttermilk to get a slurry with soy-solids-buttermilk solids ratio 2:1.
The slurry (12% TS) was homogenized (175 and 35 kg/cm2 at 65 oC), pasteurized (85 oC) and
inoculated with L. Bulgaricus+ S. thermophilus @2%. After incubation at 37 o C for 10-12 h, dahi
was sweetened with sugar syrup and thoroughly mixed. The resultant lassi had 10 days storage life
at 5 oC in polyethylene pouches.
Kumar et al (1987) developed a lassi type cultured beverages from cheese whey. Skim milk
and cheese whey in ratio of 5:95 were used. The finished lassi contained 21-22% TS, 3.05% protein,
17.85% carbohydrates and .3% ash.
Naresh and Prasad (1996) attempted the enhancement of shelf life of lassi apart fron cold
storage. Addition of nisin @200-300 IU/ml and 400-500/ml extended the acceptability to 24 and 32
hours respectively compared to 8hr for control at 30 o C.
Kumar (2004) developed lassi like beverage from rennent whey. It contained 67.27% whey
and standardized buffalo milk (6% fat). The beverage had 2% fat, 1.85% protein, 12.49% sucrose
and 4.54% lactose. This beverage was subjected to UHT- treatment. The milk result suggests that
milk cna be replaced by 70% panner or cheese whey in preparation of lassi like beverage.
2.4 FAT RICH PRODUCTS
Butter and Ghee are the prominent products under this section. Humans are familiar to this
product since centuries and according Indian texts, it was first mentioned in 8 th century BC. Since
that time many new technologies had been adopted for manufacturing at household and then at
commercial level product.
Nearly 90% of Ghee produced in country is made by traditional method. Increased
awareness about energy management in past motivated the research works of develop energy
efficient and continuous method for ghee manufacturing (Punjrath 1974), which include either an
oil separator (Bhatia 1978) to separate serum and fat phase or use of scrapped surface heat
exchangers (Abhichandan et al ; 1995). Both the process save energy and yield a comparable
product.
NDRI have tried to modify, scale up the traditional method of ghee making into continuous
method. The mechanized process is used for producing butter oil involving centrifuge separation of
moisture followed by final dehydration under vacuum. However, the product was lacked typical
ghee flavour.
Small Group Activity (SAG) team was constituted under TQM programme at Panchmahal
Dairy, Godhra, which worked on improvement in production technology of ghee making. The
procedure finalized with inclusion of serum separation and a spiro heater in the process. The cream
used was first pasteurized using HTST at 90-92°C and pumped to Continuous Butter Making
Machine (CBMM) where in butter is obtained. White butter is melted by pumping through Spiro-
heater. The ghee made by this process is fetching premium price in market.
 The use of FFS machine in ghee packaging is becoming very popular. In this machine,
pillow type pouches are formed, filled and sealed in one operation. It gives an output of 800-1200
pouches (500 gm or 1000gm) per hour. The pouch film used is coextruded LLDPE/LDPE or
polystyrene/nylon.
2.5 MILK BASED DESERTS/PUDDING
Consumer’s convenience along with safety is key to value addition in dairy and food
processing industry. In this context Kheer and dalia are two important cereal based food product,
which are popular throughout the country but have no organized manufacturing and marketing
system (Aneja, 1977).
Kheer is popular in northwest central and eastern parts of the country and is popular as
Payasam in the southern states. Similarly, dalia as a milk-wheat porridge is quite common is many
parts of country both as breakfast food as well as health food.
Despite of such huge popularity the cereal based sweets continue to be made much in
traditional manner only few attempts have been made to mechanize the processing technology
which include use of steam-jacketed kettle for manufacturing of kheer, using steam process. Rice
pudding has also been manufacturing employing a scraped surface heat exchange (SSHE).
A process has recently been developed at NDRI, Karnal for in-package cooking and
sterilization of kheer in retort pouches with the objective to enhance its shelf life at ambient
temperature. The kheer obtained by this process had shelf life of more than four months at 37°C.
In order to promote dalia desert as a marketable product a process has been developed for
manufacturing of instant dalia mix, use of fluidized bed drier and spray drier has been made in
manufacturing instant dalia mix. The product so developed was packed in PE-paper board cartons.
Reconstitution in boiling water yields a product, which is highly acceptable.
Mechanization in cereal milk based deserts is still required as development of suitable
process for commercial manufacturing of cereal-milk based convenience foods will hopefully
provide a necessary fillip to the contribution of traditional dairy products its national dairy
economy.
DEVELOPMENTS IN PACKAGING
The traditional dairy products have been conventionally packaged in dhak leaves, paper cartons,
polyethylene bags or cardboard boxes. These traditional packages do not provide sufficient protection to
the product from atmospheric contamination and also do not have the functional properties in order to
preserve the initial quality of the product for a longer time. As a result, the products soon loose their
typical body and texture, pick up foreign odors, become rancid/oxidized and give undesirable appearance.
These packages are also not suitable for far-off transportation and outstation retail sales (Goyal, 1998).
Recently, with the rapid developments in packaging technology, substantial progress has been
made in packaging of traditional dairy products. Packaging of Khoa in laminates of paper/[Link]/LDPE
(55-60 gsm, 0.02 mm and 159 gauge), and Polycel (300, 150 gauge poly, colored) have been found to be
quite satisfactory for Khoa. In these packages, Khoa can remain in good condition for 10 days at ambient
temperatures and 60 days under refrigeration conditions. However, by using 4-ply laminated pouches made
of PP/LDPE/ Foil/LDPE, the shelf life of Khoa can be increased to 14 days at 30ºC and 75 days in cold
storage (Kumar et al. 1975). For packaging of Chhana, polycel (300 and 150 gauge, colored) is good, low-
cost packaging material.
Ghee is generally packaged in lacquered or unlacqured tin cans of various capacities ranging from
250g to 5 kg for retail sale and 15 liters for bulk sale. Some dairies pack ghee in polyethylene bags. Other
recommended packages for packaging of ghee are polyester coated cellophane, polyester, nylon-6, food
grade PVC or their laminates.
Recently, systems have been developed for assembly line packaging for Shrikhand, Dahi, Misti
Doi, Paneer, etc. and are being used in organized sector. Polystyrene or polypropylene cups used for
packaging of Paneer extend shelf life of 180 days at -18ºC and 30 days at 5ºC. Rasogolla are being packed
in lacquered tins with a shelf life of 6 months at room temperature (Chandan et al ; 2002). Polypropylene
trays covered with transparent, coloured MXXT are recommended packages of Burfi, Peda and Kalakand
(Goyal ,1998). Low weight, leak-proof lacquered kulhers for packaging dahi, misti doi, etc. have been
developed at NDRI, which give better shelf life than plastic cups.
CONCLUSION
The Indian milk sweets enjoy mass appeal, give high profit margins and have high export
potential. There is an urgent need to modernize this sector to produce high quality products with long shelf
life. We need to generate basic data on these products which will help for designing of new equipments or
for intelligent selection of existing food processing and packaging lines. Great scope also exists for
improving the shelf life of milk sweets by employing newer preservation techniques. While lots of
innovations have taken place recently, these innovations have not percolated to the actual users. Industry-R
& D organization links need to be strengthened for designing machinery for commercial manufacture of
traditional dairy products. Innovation in marketing is equally important. It is possible to popularize
indigenous dairy delicacies through the fast food chains or franchising of some popular brands of Indian
dairy delicacies may be promoted. Collecting market intelligence to inspire confidence among prospective
entrepreneurs to take commercial production of traditional dairy products in India and abroad is also
essential. Collaborative efforts of industry, unorganized sector, equipment manufacture and R & D
institutions are required for all round development of traditional dairy product sector.
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