Amber zafar

Lab champion Engro foods Sahiwal

CompanyprofileEngro Chemical Pakistan Limited is the second largest producer of Urea fertilizer in Pakistan. The company was incorporated in 1965 and was formerly Exxon Chemical Pakistan Limited until 1991, when Exxon decided to divest their fertilizer business on a global basis and sold off its equity of 75% shares in our company. The Employees of Engro, in partnership with leading international and local financial institutions bought out Exxon’s equity and the company was renamed as Engro Chemical Pakistan Limited. Engro is a public limited company listed on the Stock Exchanges of Karachi, Lahore and Islamabad.

ENGRO FOOD LIMITED (EFL):

Engro Foods Limited is subsidiary of Engro Chemical Pvt. Ltd. It has diversified into the food business and with the successful launch of Olper’s Milk, Olper’sCream, Olwell, Owsum Milk, Tarka Ghee, Omore Ice cream. Engro Foods Limited has established itself as a major player in the foods business. Their aim is to dominate the food business. EFL has been established in 2005 as part of a diversification process at the Engro Group.

SUKKUR PLANT:

The plant located at Sukkur on 23 acre land, has the raw milk reception capability of 300,000 liters per day and UHT milk capacity of 200,000 liters per day. OwsamMilk,

Olwell Milk, Tarka Ghee, olfrute and Olper’s Cream are being manufactured here.

SAHIWAL PLANT:It is situated at 8 Km away from Sahiwal and while going to Pakpattan and when coming from Pakpattan towards Sahiwal it is 32 Km away from Pakpattan at North side of main road.Sahiwal plant was installed in 2007 and at starts its production at the end of same year. It comprises of 33 acres that contains plant portion, parking areas, landscaping areas, waste water treatment plant and neat and clean roads. It has 8 raw milk silos, 2 of them having capacity of 125000 liters and the 5 of them having 150000 liters capacity. Here in Sahiwal olpers ,Tarang,Tarang elachiOmore, and Omung are manufactured.

CERTIFICATES OWNED BY ENGRO FOODS (PVT.) LTD

MILK RECEPTION CRITERIA ON THE PLANT ENTRY: when tanker reach at plant gate an inbound and out

bound security check list is filled by the security guard . When milk tankers entered into EFL then proper record of their entrance is maintained on security slip that includes Driver name Vehicle number Size of vehicle Commodity it carry and first weight After first weight company driver who drives the tanker Up to first automatic weighting parking hand over these three slips to reception operator in admin building who attach a office copy with these and call to lab for collect sample from respective vehicle ,as soon the phone call receives at reception lab a sample boy sent for milk sampling, who is trained for this .once sampling done and results compile after analysis sample boy bring back these slips with QA Accepted stamp to reception operator ,now sample boy compile QA lab results on Other two dispatches which are plant copy and FOM copy signed by APM .

Dispatch note office copy carries information about D/s point ,area office ,name of the driver , tanker capacity Factory time in truck number , Date ,D/s time Seal number .After QA accepted stamp and Shift chemist and APM sign dispatch note tanker will receive and after milk receiving CIP will start the time of CIP start and end time and than final weight will display and print again on a slip through receiving operator .after CIP these dispatch slips and all other slips hand over to LCO (logistic Coordinator ) except one dispatch who handed over to production dept. and truck will out from second gate . WEIGHING: Where milk tanker pass through the weighed that is automatically operated. Here weight is recorded in tons and dispatch is given to driver. Weight of milk = Total Weight - Empty tanker weight Volume in liters of milk = weight in kilogram /specific gravity of that milk. Once its weighted the driver will hand over this dispatch note and security slip to production department sitting in admin building .The reception operator will give third copy to driver Who will hand over this to line lab through line lab window . Where lab analyst receive this and inform to shift chemist shift chemist will instruct to sample boy of particular shift for sampling .

sampling of Milk

Sampling is very crucial because all quality tests depend upon accuracy of

sampling. If samples are not true representatives of whole tanker then this

misleads the result that’s why EFL appointed trained persons for collection of

samples.

SAMPLING PROCEDURE: Following steps are taken by the person who is taking sample: Seals of the tanker are checked (either broken or not) . After this check he will take plunger and knoppy and will wash them with 70% Ethanol dry them than he will hook up the safety harness within the sides of trucks and ensure that it is hooked properly . Than he will start Agitation with the help of plunger for about two to three minutes for representative sample . He will take about a liter sample from each portion of the tanker in washed and labelled utensils. Samples are brought to reception lab immediately where these are analyzed for various parameters. At the time samples received in lab temperature . sample analysis will done and results

announces Within 45 minutes .

ANALYSIS OF FRESH MILK: Analysis comprises of following types of tests: A. Organoleptic Tests B. Qualitative Tests C. Quantitative Test D. Adulteration Tests

A. ORGANOLEPTIC TESTS:

Organoleptic evaluation of the milk includes, taste, odor, smell and color. Normal milk has slightly sweet, no objectionable odor and pleasant taste. If milk is not fresh its lactose content is converted into lactic acid due to bacterial activity. Color of milk is white due to dispersion of casein and fat which does not permits light to pass through it. For Organoleptic evaluation milk is first heated to 40oC because of the fact that molecules become active and volatile compound present in milk are evaporated and make the evaluation easy.

B. QUALITATIVE TEST.

1. TEMPERATURE: After taking sample, immediately temperature of the milk is noted. The temperature of the milk should not be more than 10oC. If it varies from this, warning should be issued to the milk supplier or respective area collection center. 2. COB When normal milk is heated it does not form clots. However if milk is abnormal, milked from diseased animal (mastitis), rich in colostrum, very high in salts (NaCl) or high in acidity (>0.30% lactic acid) it forms clots or curdles on gentle boiling. Such milk cannot stand the heat temperature in milk processing. 2-4ml milk in test tube is heated and clotting, coagulation or precipitation is observed. If any of above mentioned property is observed it means milk sample has failed the test and milk is suitable for further processing.

3. pH OF MILK: pH of fresh milk ranges 6.65-6.85 but when milk comes in contact with environment bacterial activity starts and due to production of certain acids pH of milk decrease. pH of milk is measured at EFL with the help of digital WTW pH meter. Acceptable range of pH at EFL plant is 6.6-6.9. 4. ACIDITY OF MILK:

Majority of the bacteria that grows in milk develop acidity through lactic acid fermentation leading to souring, curdling of milk. In the acidity test the acid is neutralized with 0.1 N Sodium Hydroxide and the amount of alkaline is measured. From this, the percentage of lactic acid can be calculated. Fresh milk contains in this test tube also” natural acidity” which is due to the natural ability to resist pH changes. The natural acidity of the milk is 0.110-0.150%. Figure higher than this signifies developed acidity due to the action of the bacteria on the milk sugar. At EFL milk reception criteria allow only milk to be received of it has acidity in range of 0.110-0.150% (as a lactic acid); values higher than this are not entertained for reception.

5. APT @ 60 APT @90PURPOSE:To test the quality of raw milk for processing .PRINCIPLE: Alcohol precipitate test (APT) is quick and simple, based on in stability of the protein when the levels of the acid and/or rennet are increased and the aqueous alcoholic solution of known concentration is added an insoluble precipitate is formed.

C. QUANTITATIVE TESTS:

1-FAT % DETERMINATION It( includes fat%, protein %, SNF % )PURPOSE: To determine fat content in milk since the fat content of the milk and cream is the most important single factor in determining the price to be paid for milk supplied by farmers in Pakistan. Fat test are also done on milk products in order to make accurate adjustment of the butterfat percentage in the standardized milk products. Fat determination at plant is also calculated for loss/gain calculation of plant for production strategies and in procurement.

2-PROTEIN DETERMINATION: PURPOSE: Proteins are the most vital component of milk and part of SNF component of milk. Lactose, Proteins, Ash is present in a fixed ratio know as Vieth’s ratio that is 13: 9: 2. We can infer quality of milk by observing any change in the Vieth’s ratio through the determination of protein content of milk and not only monitor quality of milk, avoid adulteration such as SNF forging with the addition of Sugar, salt etc) but can also develop a multi component fresh milk payment formula based on SNF, Protein and Fat instead of prevailing practices of milk payment on the basis of Fat alone. Formal titration is one of the quickest and semi quantitative methods to determine protein percent of milk in field. It does not require high skill, specialized equipment and is reasonably inexpensive. In this test it is assumed that the formalin used in this test binds all the acids present in milk and remaining acidity is due to proteins in milk.

3. MSNF CALCULATION: PURPOSE: Determination of milk solids non fat (MSNF) and total solids in liquid milk for material balance and some time for pricing of milk as well.

CALCULATION AND EXPRESSION OF THE RESULTS MSNF % = (0.25 x CLR) + (0.22 x Fat %) + 0.72 TC % = Fat %+MSNF % Where LR=lactometer reading Fat = Fat % in milk sample MSNF= Milk solids non fat TC=Total solid content

D. ADULTERATION TESTS: 1. TEST FOR DETECTION OF HYDROGEN PEROXID2. TEST FOR DETECTION OF SUGAR IN MILK3. TEST FOR DETECTION OF STARCH4. TEST FOR DETECTION OF GLUCOSE5. TEST FOR DETECTION OF UREA6. TEST FOR DETECTION OF SALT 7. DETECTION OF VEGETABLE FAT IN MILK 8. TEST FOR DETECTION OF SORBITOL1 9. AMMONIUM SULPHATE10. AMMONIUM NITRATE11. FORMALINE12. BARFORD13. DETERGENT TEST

1. DETERGENT TEST: In milk neutralizers like hydrated lime, sodium hydroxide, sodium carbonate or sodium bicarbonate are added which are generally prohibited. HOW TO DETECT? Take 2ml of milk in a test tube and add 2 ml alcohol (95% ethanol) followed by 2-3 drops of rosalic acid. If the color of milk changes to pinkish red, then it is inferred that the milk is adulterated with sodium carbonate / sodium bicarbonate and hence unfit for human consumption. This test will be effective only if the neutralizers are present in milk. 2. TEST FOR DETECTION OF HYDROGEN PEROXIDE: For the determination of hydrogen peroxide strips are used which develop color on presence of H2O2.

3. TEST FOR DETECTION OF SUGAR IN MILK: Generally sugar is mixed in the milk to increase the solid not fat content of milk i.e. to increase the lactometer reading of milk, which is already diluted with water. HOW TO DETECT? 0.5ml milk + 3ml 37% HCl+ few drops of 10% alpha-naphthol, boil for 10 second and observe color, if no color sugar absent, blue violet color indicate added sugars in milk. 4. TEST FOR DETECTION OF STARCH: Addition of starch also increases the SNF content of milk. Apart from the starch, wheat flour, arrowroot, rice flour is also added. HOW TO DETECT? 2-4ml of milk sample + few drops of 0.1% iodine solution and observes color, if blue color appears, starches are present.

5. TEST FOR DETECTION OF GLUCOSE: Usually poor quality glucose is added to milk to increase the lactometer reading. There are two tests available to detect the adulteration of milk with glucose. HOW TO PROCEED? Glucose strips are used to detect the glucose in milk. Color scale on the pack indicates the amount of glucose. BARFORD TEST: 2.5ml milk + 5ml barford reagent (copper acetate), dip in boiling water for 3 minutes and observe color, if no color change then glucose is absent, and if greenish color with brownish sedimentation appears glucose is present in milk.

5. TEST FOR DETECTION OF GLUCOSE: Usually poor quality glucose is added to milk to increase the lactometer reading. There are two tests available to detect the adulteration of milk with glucose. HOW TO PROCEED? Glucose strips are used to detect the glucose in milk. Color scale on the pack indicates the amount of glucose. BARFORD TEST: 2.5ml milk + 5ml barford reagent (copper acetate), dip in boiling water for 3 minutes and observe color, if no color change then glucose is absent, and if greenish color with brownish sedimentation appears glucose is present in milk.

6. TEST FOR DETECTION OF UREA: 1. Urea is generally added in the preparation of synthetic milk to raise the SNF value. Strips are used to detect urea in milk sample. 2. 2ml milk sample + 2 ml DMAB solution, observe the color. Yellowish color shows the presence of urea.

7. TEST FOR DETECTION OF SALT: Addition of salt in milk is mainly resorted to with the aim of increasing the corrected lactometer reading. HOW TO DETECT? 9ml milk sample + few drops of K2Cr2O5 (10%) and titrate against 0.1 N AgNO3 and note the BR and multiply against 0.00584 to calculate salts % (as NaCl).

8. TEST FOR DETECTION OF SORBITOL: Generally sorbitol is mixed in the milk to increase the solid not fat content of milk i.e. to increase the lactometer reading of milk, which is already diluted with water. HOW TO DETECT? 1 ml milk sample + 2ml, 10% NaOH sol. + 2ml, 10% iron sulphate sol. Mix well and note the color and gel formation, if yellow green color and gel formation appears then test is +ve.

9. DETECTION OF VEGETABLE FAT IN MILK: The characteristic feature of milk is its fatty acid composition, which mainly consists of short chain fatty acids such as butyric, caproic, caprylic acid; whereas the vegetable fats consist mainly of long chain fatty acids and hence adulteration of vegetable fat in milk can be easily found out by analyzing the fatty acid profile by gas chromatography. At EFL vegetable fats are detected by using Butyro-refrective Index meter which is calibrated at 41 with liquid paraffin at 40oC. Fat from the milk sample is collected in spoon.after centrifugation and heated on sprit lamp to evaporate moisture. A drop of fat is spread on stage of BR meter and reading is noted from the scale. The acceptable range of EFL is 39 to 43 and Values more than this indicates that the milk has been adulterated with vegetable fat. After complete analysis a sheet is prepared known as Raw Milk Reception Sheet. If entire milk fulfills all criteria then, it is mentioned as accepted otherwise rejected. Analyst then (May be more than one with one supervisor) put his signature on this sheet. Then these results are compared with results of analysis made at area collection center before its dispatch from area and variation is mentioned on raw milk reception sheet. Now milk tankers are weighed on a Weigh Bridge and are hooked to reception point of plant where loading hose of silo pump is attached

to outlet of tank.

MILK PROCESSING:Milk processing steps are these in EFLMilk ReceptionMilk StorageMilk PasteurizationUHTAseptic PackagingPackaging Materials

Farmer Dairy

Production

Retailer

Dairy

Raw Material, Packaging, Service

Wholesaler

Dist. Centers

Broker

Sell Raw Material and Ingredients

Supplier

Add. Purchase of Raw Material / Raw Milk

Consumer

Reception Tanker Flexible pipe

Raw Milk silos (Temp >10)

Raw Milk Silos Plate Heated

Exchanger 55 C

Separator

SlugeCream

45%

Skim Milk fat 0.05%

Raw Cream storage tank

Premix

Premix Additives Sugar

Raw milk Silos Temp >10 c

Holding Tube 3c

Main heater

75c

Deaerator 65-70

Homogenization 1st Stage 100 bar

2nd 50 Bar 60c – 65c

Hydrogenated palm oil

Pasturizemilk silos

>10

Thermal heat exchanger 92 c+-3

Protein stabilizer120 c

Thermal exchange exchanger

Main heater 140c + -4 c

Holding Tube 2 seconds

THE 25 c ATS

Filling Machines

Total Five ATS at Packaging with capacity and machines .ATS 1 (35000)ATS 2 (40000)A,B.D,omung (T 20 ) Tarang , Tarang ElachiATS -3 (50000)X,Y,Z,Ecolan,F,V,A2,B2,C2ATS4 (50000)G,H,I,J,L,M,N, Tarang F2ATS -5 (50000)O,P,Q,R,S,T, Tarang One StepATS-6 (50000)E2,D2,G2

Raw milk silos

RMT 1 125,000 LTRS

RMT 2 125,000 LTRS

RMT 3 150,000

LTRS

RMT 5 150,000

LTRS

RMT 6 150,000

LTRS

RMT 6 150,000

LTRS

RMT 7 150,000

LTRS

RMT 8 150,000

LTRS

RCT 1 10,000 Kg

RCT 2 10,000Kg

RCT 3 20,000 kg

RCT 4 7500 Kg

RCT 5 7500 Kg

Raw Cream Storage Tanks

PC 1 10,000 Kg

PC 2 10,000 Kg

PC 3 10,000 Kg

PC 4 10,000Kg

PC 5 10,000Kg

PC 6 30,000 Kg

PC 6 30,000Kg

PC 7 30,000 Kg

PC 8 30,000 Kg

Pasteurized Cream Tanks

Premixes Tanks

M2 20,000 LTRS

M3 20,000 LTRS

M4

20,000LTRS

SM1

20,000LTRS

SM2

20,000

LTRS

SM3

20,000

LTRS

PMT 1 75,000 LTRS

PMT 2 75,000LTRS

PMT 3 75,000LTRS

PMT 4 75,000 LTRS

PMT 5 75,000LTRS

PMT 6 75,000 LTRS

PMT 7 75,000 LTRS

PMT 8 10,0000 LTRS

PMT 9 10,0000 LTRS

PMT 10 10,0000 LTRS

Pasteurize Milk Tanks

Micro Lab orientation starts from 14-09-15 to

Portions 1- wet lab (For washing purpose of utensils and drying of utensils )(Equipment's) 1-Oven 2-auto clave 121 c for 15 minutes )3-water bath (37c)

2-Sterlization Room Fridges <10 c <20c Micro wave ovenAuto clave (out of order)PH meter Somatic cell counter Weight balance 3200 g-0.5 g Oven170 c3-Inoculation RoomLaminar flow (purpose for inoculation of plates and having UV light)It is also termed as Laminar Flow Clean Bench.Here UV rays were used to sterilize surrounding air.

Thermometers wet bulb dry bulb Fridge.

Incubation Room 1- incubators

MICROBIOLOGICAL LAB:

This Microbiological Lab was very important lab of the quality assurance department. In this lab, the microbiological quality of the Ice cream, UHT milk, pasteurized milk and raw milk is measured by following techniques,Pour plate method Spread plate methodStreak plate method

There were several incubators which were favorable to growth as they have Moist Air.

MICROBIOLOGICAL TESTS:Different tests are performed for different products in EFL and these are given here below:

Raw milk:MBRT

TPC(5th or 6th dilution)EB’s(4th dilution)

Somatic CellAntibiotics

Yeast and mold(Special case and on 4th dilution)Pasteurized Milk:TPC(2nd dilution)EB’s(2nd dilution)

PhosphataseUHT Milk(1st dilution):

TPCEB’

Milk powder:EB’s(1st dilution)TPC(2nd dilution)

Yeast and mold (1st dilution)Ice cream(1st dilution):

TPCColiform

Environmental monitoring:Swab test( Machine+ person on 1st dilution))

MICROBIOLOGY ROOM HAS THE FOLLOWING EQUIPMENT’S AND SECTIONS:AUTOCLAVE ROOMThis room is used for Media preparation.Temperature =121oCPressure=15psiSet time=15 minutes

In this room there is an oven operated at 170oC and used for sterilization of equipment's.Another oven that operates on 100oC and used for sterilization of stainless steel and plastic equipment'sA water bath having temperature 52oC.Hygiene auditing.

INOCULATION ROOM

It is also termed as Laminar Flow Clean Bench.Here UV rays were used to sterilize surrounding air.

INCUBATION ROOM

There were several incubators which were favorable to growth as they have Moist Air.MICROBIOLOGICAL TESTS:Different tests are performed for different products in EFL and these are given here below:Raw milk:MBRTTPC(5th or 6th dilution)EB’s(4th dilution)Somatic CellAntibioticsYeast and mold(Special case and on 4th dilution)Pasteurized Milk:TPC(2nd dilution)EB’s(2nd dilution)PhosphataseUHT Milk(1st dilution):TPCEB’

Milk powder:by the dilution technique

UHT Milk(1st dilution):TPCEB’Milk powder:EB’s(1st dilution)TPC(2nd dilution)Yeast and mold (1st dilution)Ice cream(1st dilution):TPC/ColiformEnvironmental monitoring:Swab test( Machine+ person on 1st dilution))DILUTION PREPARATIONS:

Purpose:To prepare an appropriate dilution of a sample so that 1ml will contain 30-300 colonies when inoculated in a Petri dish.Principle:In determining the microbial content of milk, milk products, water and rinse and swab from dairy utensils and equipment, serial dilutions of the sample is prepared. The measured amount of the prepared dilution when inoculated in a Petri dish and grown on agar medium should contain 30-300 colonies. The ten-fold serial dilution (1ml of sample diluted with 09 ml diluting solution) can be prepared by the dilution technique

UHT Milk(1st dilution):TPCEB’Milk powder:EB’s(1st dilution)TPC(2nd dilution)Yeast and mold (1st dilution)Ice cream(1st dilution):TPCColiformEnvironmental monitoring:Swab test( Machine+ person on 1st dilution))

DILUTION PREPARATIONS: Purpose:To prepare an appropriate dilution of a sample so that 1ml will contain 30-300 colonies when inoculated in a Petri dish.Principle:In determining the microbial content of milk, milk products, water and rinse and swab from dairy utensils and equipment, serial dilutions of the sample is prepared. The measured amount of the prepared dilution when inoculated in a Petri dish and grown on agar medium

should contain 30-300 colonies. The ten-fold serial dilution (1ml of sample diluted with 09 ml diluting solution) can be prepared by the dilution technique

MBRT: Methylene Blue Reduction Test is used in order to check the keeping quality of finished and raw milk. However this is mostly used for finished product. Aerobic bacteria present in the milk reduce the color of dye by oxidation reduction. More the aerobic form of bacteria less will be time required for color to disappear.10ml milk sample in sterile test tubes is taken and 1ml of MBRT solution is added and were placed in water bath at 37°C After every five minutes color change is observed and time is noted when whole of the color disappears and is reported as” hours-methylene blue reduction time”.

TPC-TOTAL PLATE COUNT: It is done for Estimation of viable and non-viable microbes present in fresh milk for microbiological quality, hygiene monitoring and payment of quality characteristics of fresh milk. For this test, TPC media is prepared and diluted milk sample inculcated and incubated.

EB’S - COLIFORM COUNT:Purpose:To detect the presence of Escherichia coli in milk, milk products, dairy equipment and water supply.Principle:The group of coliform microorganisms includes the genera Escherichia and Agrobacteria. The widespread distribution of coliform in nature, feeding itself on available food of its habitat, permits a minimal occurrence of these microorganisms in milk, milk products, and surfaces of dairy equipment, air and water supply. A large number of these bacteria indicate poor hygiene and negligence. Proper heat treatment is sufficient to destroy the coliform bacteria, and its presence in pasteurized milk and milk products serves as index of recontamination or post pasteurization contamination largely due to poor hygienic practices.

The coliform bacteria were a Gram-negative rod, and its ability to produce acid and gas as products of lactose fermentation is the prime basis of laboratory tests for detecting it in a sample. The medium used contain a bile salt which prevents the growth of the Gram-positive organism.

SOMATIC CELL COUNT: Somatic cells were blood cells that fight infection and occur naturally in milk. The presence of mastitis (an infection of the mammary gland) in the cow will increase the somatic cell count. The somatic cell count can be determined by direct microscopic examination or by electronic instruments designed to count somatic cells. The count can be measured on bulk tank milk or on individual cow. California Mastitis Kit is used for this purpose by EFL microbiologist while monitoring milk quality at root level, i.e. on individual cows. Normally count of somatic cells found in milk is low (1, 00,000 cells/ml).

ANTIBIOTIC RESIDUES: Antibiotics were commonly used to treat mastitis or other conditions in cows. Each antibiotic preparation has a specific withdrawal time from meat and milk. The withdrawal time is time from the last treatment with the antibiotic until the milk is permitted to be put in the bulk tank for shipment to the processor. At EFL Standard Diffusion Test is used for the detection of residual antibiotics. 0.2ml milk sample is transferred in special capped tube with the help of syringe provided in test kit.Now place at 65oC in water bath and observe color.Results:

If purple or blue color appears, test is positiveIf green color appears, test is negative.

ICE CREAM MANUFACTURING:O’more Ice Cream is a famous ice cream brand in Pakistan. O’morehas a fully automatic ice cream manufacturing facility, and has a production capacity capable of producing more than 4.5 million liters of dairy ice cream a year. O’more Ice Cream produces a variety of flavors, including chocolate, vanilla, mango, strawberry, orange, kulfi, caramel as well as many more

Mixing of igredients

Pasteurization (85°C for 15min)

Homogenization (1500-2000

bars)

Rapid Cooling (7-8°C)

Aging (4°C)

Colour and Flavoring Tank

Freezing

Filling

Hardening (-28°C)

Cold Storage (-18°C)

PHYSIOCHEMICAL LAB:First of all I will discuss about physiochemical lab. Here different projects are given to me. Now I will discuss these projects. These projects are:Water analysisWastewater analysisSolution preparationEquipment verificationEquipment calibration

PHYSIO LAB

WATER ANALYSIS:

In EFL Sahiwal, tape water comes after treatment so water analysis is

being done to checked the efficiency of water treatment. For this I

checked the water by using different chemical tests after every step of

water treatment. I performed water test for consecutive 10days.The

water treatment steps that efficiency I have checked . It includes

Sr. No.Steps Tests

01Raw water pH test, TDS test and Hardness test

02Ro water pH test, TDS test and Hardness test

03Chlorinated water pH test, TDS test and Hardness test

04DE chlorinated water pH test, TDS test and Hardness test

05Treated water pH test, TDS test and Hardness test

WATER ANALYSIS:In EFL Sahiwal, tape water comes after treatment so water analysis is being done

to checked the efficiency of water treatment. For this I checked the water by using different chemical tests after every step of water treatment. I performed water test for consecutive 10days.The water treatment steps that efficiency I have checked include.pH AND TDS TEST:pH is measured at EFL with the help of digital WTW pH meter. TDS is measured at EFL with the help of TDS meter(HACH TDS 2C5).HARDNESS TEST: For hardness, Hardness kit is used. The hardness level as mg/L (ppm) calcium

carbonate is determined by an EDTA (ethylene-diamine-tetracetic acid) titration. The solution is first adjusted to a pH of 10 using a buffer solution. The indicator chelates with metal ions such as magnesium or calcium to form a red colored complex. As EDTAis added, metal ions complex with it. After all the free metal ions have been complexed, an excess EDTA removes the metal ions complexed with the indicator to form a blue colored solution. This color change from red to blue is the endpoint of the titration and multiply the reading with 300.

WASTEWATER ANALYSIS:

In Engro food Sahiwal, before the disposal of wastewater different tests are performed to meet the environmental regulatory authorities. For wastewater treatment plant (WWTP) is made. Following operations are done in this plant.

Waste water

Screening(to remove coarse particles)

Equalization(maintain the pH)

DAF(fat removed)

Aeration Basin(72hrs stay time)

Clarifier(sludge settle onbottom) Discharge of

wastewater(by pump)

To check the efficiency of WWTP, samples are collected from different stages

and tested according to SOPs.Tests that I have performed are given here below:

Sr.

No.

Steps Tests

01 Clarifier pH, TDS, BOD, COD and FOG

02 After DAF pH, TDS, BOD, COD,phosphate, FOG

03 Aeration Basin pH,TDS, SV, SVI,TSS,MLSS, DO

04 Sludge(New) TSS,MLSS

05 Sludge(old) TSS,MLSS

COD:COD is checked by number of steps. Firstly Clarifier and DAF samples are filtered and then 2mL of sample Is added in Hanna COD reagents vials and mix it. Then these are placed in COD reactor for 2hrs at 150 temperature for digestion. After this Vials are removed from reactor and cooled at room temperature and then placed at millimeter bench photometer and note the reading

BOD:

For BOD, 156 mL sample after filtration is placed in Lovibond BOD bootles and

add metallic tablet for stirring in BOD apperatus and placed in BOD apperatus for

incubation and check the reading the reading after 5 days.

EFFLUENT WATER STANDARD PARAMETERS (NEQS):

Parameter Units NEQS

pH ---- 6-9

TSS mg/l 200

BOD mg/l 80

COD mg/l 150

1. SPECIAL WATER TESTS:

In addition to above these tests,Boiler and Ammonia condenser water is checked

to avoid the corrosion and any other trouble shooting in equipments.

These tests include:

Sr. No. Equipment Tests

01 Boiler feed water pH, TDS, Hardness

02 Boiler blow down water(3

boilers)

pH, TDS, Hardness,

Alkalinity,

sulfite, iron and Phosphorus

test.

03 Ammonia Condensor

water(3 condensors)

pH, TDS, Hardness

PHOSPHORUS AND IRON TEST:Phosphorus is checked by addition of Hanna instruments HI 736-25 phosphorus and iron reagent in tube and it is compared with Hana comparator. If phosphorus reading is multiplied with 0.326 then we get phosphate reading.ALKALINITY TEST:The Alkalinity is determined by neutralizing the sample to a pH of 8.3 using a dilute hydrochloric acid solution, and a phenolphthalein indicator. It is then titrated with HI 3811-0 solution. Read off the milliliters of titration solution from the syringe scale, and multiply by 300 to obtain mg/L (ppm) CaCO3.

SOLUTION PREPARATION:In physiochemical lab, solutions are also prepared. There are 3 kinds of solutions thai I made.PERCENT SOLUTION:Except alcohol all chemicals are not 100% pure. Following formula is used for percent solution:C1V1=C2V2

by metallic stirrer.NORMAL SOLUTION:

1 Normal solution is solution in which gram equivalent weight of chemical dissolved in 1 liter. A number of normal solution is made in physiochemical lab by following formula:For Solids:N=Required normality*gram equivalent weight of compound*required volume/1000For Liquids:N=%purity of given solution*specific gravity*1000/gram equivalent weight of compound*100N1V1=N2V2For example 0.1 N NaoH of 2liters is made by 80 grams of Noah in volumetric flask and volume make up by distilled water up to 2litters

MOLAR SOLUTION:Molar solutions are also frequently made in physiochemical lab. It is made by weight equal to molecular weight added in volumetric flask and volume make up to 1liter to made 1 molar solution. 3 molar KCL solution is used for keeping the pH electrode in case of not use.

EQUIPMENT VERIFICATION:In physiochemical I also verified different different labs equipment in coordination with lab analyst. I have verified butyrometers, pipettes, pH meters, lactometer, electric weighing balance etc. These are checked with master piece of equipment that is certified by reputable company. For example in case of butyrometer,it is verified with the help of Dr. Gerber certified butyrometer by testing the fat with both equipment's. If difference is major then rejected.

EQUIPMENT CALIBRATION:I also verified different labs equipment in coordination with lab analyst. I have calibrated pH meters and TDS meter. pH meter error is cleared by proper cleaning of electrode or by changing the electrode

RAW PACKAGING AND TECHNICAL MATERIALS LABHere packaging material that is used for raw packing is checked with the technical point of view.Packaging lab falls under the quality assurance lab. In this lab following tests were performed.

Analyze the design of the package•Analyze the reel width•Analyze the reel diameter (external)•Analyze the core diameter (internal)•Analyze the length of the sign detected by the photocell•Analyze the width of the sign detected by the photocell•Gramm age (g/m2) determination•Aroma test

MILK POWDER ANALYSIS:There are two types of milk powder which are tested; Skim milk powder and Full cream milk powder. On powder following tests are conducted;Fat %ageMoisture %ageBulk DensityAcidityPH & OR-P FAT DETERMINATION OF MILK POWDER:Fat is determined by Gerber method, i.e. 10ml conc. H2SO4 (92%) +1.69g powder (in case of using 8% butyrometer) or 2.50g (in case of using butyrometer of 35%) + 1ml Iso-amyl alcohol. Centrifugation at 1180rpm for 5-6mintes at 65 oC is given to separate the fat from milk. Reading of the butyrometer gives fat in percent's.If butyrometer of 8% is used then final reading is multiplied with 20/3.In Glorious Skim Milk Powder fat appears as 25-27% while in Glorious Full Cream Milk Powder appears as 1-1.5%.

MOISTURE %AGE:Moisture %age in final product is very important because of the fact that shelf life of the product in storage is greatly influenced by the amount of moisture present in that food article. In case of milk powder moisture in the final product is kept in range of 1.2% to 1.70%.Procedure: 2.5g milk powder is weighed in aluminum boat from which moisture already has been removed. The temperature of moisture of moisture analyzer is set to auto (101-104 oC for 3-4 min) or at 90oC for 6min. Moisture analyzer directly gives the moisture in percent's.

BULK DENSITY:Weight by volume ratio of powder is called as bulk density of powder. It shows degree of compactness of powder.Procedure: 28g of powder is weighed into a graduated plastic cylinder of 250ml capacity. Now place cap on the cylinder and tap the cylinder 25 times on shelf and note volume from the top level. Divide the weight by volume to get bulk density of powder.

ACIDITY OF POWDER: Acidity of powder is measured as lactic acid activity.Sample Preparation: 10g of SMP or 13g of ISMP is dissolved in 100ml distilled water in beaker and is kept for an hour. After sample preparation proceed in the same way as in liquid milk.Procedure: 8.8ml of sample solution is taken in beaker. Then add 2-3 drops of phenolphthalein as an indicator. Titrate against 0.1N NaOH until light pink color appears or pH meter shows reading of 8.4.Calculation: No. of ml of NaOH used / 10 = % as Lactic Acid pH & OR-P: Digital pH meter is used to measure pH and OR-Potential of prepared sample of powder.WETTABILITY: Apparatus: Balance (.01 Sensitivity), Hollow Plastic Cylinder, Beaker 500 ml, Stop watch.Procedure: 250ml water is taken 500ml beaker.A hard plastic sheet is placed on lower side of cylinder.15g powder is weighed in cylinder blocked at one end by plastic sheet clumped with stand.

Remove plastic sheet and start stop watch. Stop the stop watched when all powder has been wetted.Calculations: Wettability = Time taken in second for complete wetting.

SOLUBILITY INDEX OF MILK POWDER: Apparatus:Balance (0.01 sensitivity)Solubility index tubes, Centrifuge machine, Funnel Procedure:Weight about 10g of skim milk powder or 13g of full cream milk powder and transfer to 100ml beaker at 24 oC in 500ml beaker.Mix the content and wait for 15 minutes.Fill the solubility with this sample and place them in centrifuge machine for 5 min by setting the solubility program of Gerber machine.After first centrifugation drain out sediment free liquid from tubes.Again fill the tubes with distilled water up to mark and disperses sediments with the help of thin wire.Again place tubes in centrifuge for 5min and drop liquid portion of the tubes.

Now measure the sedimentation in milliliters.

• SUGGESTIONS AND RECOMMENDATIONS:• Following are the suggestions and recommendations for

improvement :• The co-ordination between different departments should

increase in QA and QC. • The activities like customer satisfaction day should be

performed on regular basis so the company should know the feedback and satisfaction level of customers regarding the product and the image of the company.

• EFL has documented the safety related documents but continuous training ,incentive and grooming required for all lab champions.

• The tiers of tankers coming to the plant should be dipped in disinfectant first.

• With respect to Microbiology lab, tests for identification of micro-organisms should also be performed. Because it is very important to check the virulence.

• pH and Temperatures during testing should also be obtained more consciously.

• There should minimize the mouth pipetting .• A drain pipe should attach with fume hood to drain the but tyro• meters waste in fume hood while fume hood on .• Apt should take seriously in packet milk and performed .• There should be sample bottles for water and waste water .• There must be an oven for desiccation and drying in physio lab.• There must be PH meter of Orion or met Rohm in physio lab .• RPT Lab must have there own moisture analyzer .• Sink should be provided in QA lab .• A new spectrophotometer is required in KQ Lab .• Burettes should be replace by auto measures .• Thank you