PROJECT REPORT

ON

PRODUCTION PROCESS TECHNOLOGY AND PACKAGING

OF LASSI

NASREEN JABEEN

CENTRE FOR AGRI-BUSINESS MANAGEMENT

FACULTY OF AGRICULTURE

BIRSA AGRICULTURAL UNIVERSITY

KANKE, RANCHI-834006 (JHARKHAND)

2015

PROJECT REPORT

ON

PRODUCTION PROCESSS TECHNOLOGY AND PACKAGING OF LASSI

SUBMITTED TO

CENTRE FOR AGRIBUSINESS MANAGEMENT

FACULTY OF AGRICULTURE

BIRSA AGRICULTURAL UNIVERSITY

RANCHI (JHARKHAND)

BY

NASREEN JABEEN

IN PARTIAL FULFILMENT OF THE REQUIREMENTS

FOR THE DEGREE OF

MASTER OF BUSINESS ADMINISTRATION IN

AGRIBUSINESS

REGISTRATION No: - MBA/BAU/ 6955 /2013

2015

CENTRE FOR AGRIBUSINESS MANAGEMENT

FACULTY OF AGRICULTURE

BIRSA AGRICULTURAL UNIVERSITY

RANCHI – 834006 (JHARKHAND)

CC EE RR TT II FF II CC AA TT EE

This is to certify that the work recorded in the project report entitled

“PRODUCTION PROCESS TECHNOLOGY AND PACKAGING

OF LASSI’’ submitted in partial fulfillment of the requirements for the degree of MASTER

OF BUSINESS ADMINISTRATION IN AGRIBUSINESS of the Faculty of Post-Graduate

Studies, Birsa Agricultural University, Ranchi (Jharkhand) is the record of the bona fide project

work carried out by Ms. NASREEN JABEEN under my guidance and supervision. No part of

the report has been submitted for any other Degree or Diploma.

It is further certified that such helps or information received during the course of this

investigation and preparation of the report have been duly acknowledged.

ENDORSED

________________

Dr. C.S. Singh

Major Advisor

___________________

Dr. Hari Haran

Consultant Director

Centre for Agribusiness Management

BIRSA AGRICULTURAL UNIVERSITY

RANCHI – 834006 (JHARKHAND)

(Certificate of the Advisory Committee members and Endorsement of Dean, Agriculture)

CC EE RR TT II FF II CC AA TT EE

We, the undersigned members of the Advisory Committee

of Ms. NASREEN JABEEN, a candidate for the degree of MASTER OF

BUSINESS ADMINISTRATION IN AGRIBUSINESS have gone through the

manuscript of the thesis and agree that the thesis entitled, “PRODUCTION

PROCESS TECHNOLOGY AND PACKAGING OF LASSI” may be

submitted by Ms. NASREEN JABEEN in partial fulfillment of the requirement

for the degree.

…………………………

Dr. C.S. SINGH

Major advisor

...................................... Members of the Advisory Committee Dr. Hari Haran Consultant Director 1. .....................................

Centre of Agribusiness Management Dr. B.K. Jha 2. ……………………….

ENDORSED Dr. (Md.). I.A. Ansari

..................................... 3. ......................................

Dean Dr. Pramod Rai Faculty of Agriculture

BIRSA AGRICULTURAL UNIVERSITY

RANCHI – 834006 (JHARKHAND)

(Certificate of approval by the Chairman of the Advisory Committee and External

Examiner)

CC EE RR TT II FF II CC AA TT EE

This is to certify that the work recorded in this report entitled

“Production Process Technology and Packaging of Lassi” Submitted

by Ms. NASREEN JABEEN in partial fulfillment of the requirements for the

Degree of MASTER OF BUSINESS ADMINISTRATION IN

AGRIBUSINESS of the Faculty of Agriculture, Birsa Agricultural University,

Ranchi (Jharkhand) was examined and approved on ………………2015.

Dr. C.S. Singh Dr. B.K. Jha External Examiner

Major Advisor

Dr. (Md.) I.A. Ansari Dr. Pramod Rai

Dr. Hari Haran

Consultant DiRECTOR

Centre for Agribusiness Management Dr. Z. A. Haidar

DRI-cum-Dean PG

Birsa Agricultural

Ranchi

ACKNOWLEDGEMENT

First and foremost I consider it my privilege to express my deep admiration and immense

gratitude to my advisor and chairman of Advisory Committee Dr. C.S. Singh (Assistant

Professor cum Junior Scientist, Department of Agronomy, BAU, Ranchi) for his constructive

criticism during project evaluation which helped me to make necessary improvements.

I am deeply indebted to my minor advisor yet taking major initiatives and providing

guidance to improve my project report, Dr. (Md.) I. A. Ansari, (Assistant Professor cum Junior

Scientist, Department of Agricultural Engineering, RAC BAU, Ranchi).

I express my profound sense of gratitude and highly obliged to, Dr. Hari Haran,

(Consultant Director, CABM, BAU, Ranchi) for his help, guidance, fruitful suggestions and

encouragement throughout the period of investigation.

I express my sincere gratitude to Dr. Raghav Thakur (Dean, Faculty of Agriculture,

BAU, Ranchi), Dr. B.K. Jha, (Assistant Professor – Cum - Jr. Scientist, Agricultural Extension,

BAU, RAnchi) and Dr. Pramod Rai, (Assistant Professor Cum Junior Scientist, Department of

Agricultural Engineering, BAU, Ranchi) for their moral support as well as needful suggestion

throughout the course of my degree programme.

I feel privileged in expressing my gratitude to Mr.C.K. Singh (Sudha Dairy) for

providing the opportunity to work with them and providing necessary facilities and consistent

support leading to timely complete my project work.

It is my great pleasure to extend my profuse thanks to Md. Islam (Technical Assistant,

CABM, BAU, Ranchi) for his help and cooperation without whom I would never be able to

complete my degree. I wish to express my heartfelt appreciation to my parents and friends for

their blessing and inspiration in the completion of this project.

Above all, I bow down my head and offer my heartfelt devotion to the "Almighty God"

for his sacred blessings and enlightment in my life.

NASREEN JABEEN

CONTENTS

Chapter No.

Title of Chapter Page No.

List of Tables

List of Figures

ABSTRACT

1. INTRODUCTION 1-3

2. REVIEW OF LITERATURE 4-10

3. METHODOLOGY 11-22

4. FINDINGS 23-27

5. SUMMARY AND CONCLUSION 28-29

6. SUGGESTIONS 30

7. BIBLIOGRAPHY 31-33

LIST OF TABLES

Table No. Details of table Page No.

2.1 Proximate Composition of Lassi 04

3.1 QQ Quality Rating used in M.B.R.T 12

3.2 Capacity of Silos 12

4.1 Quality Parameters of Pasteurized Milk 23

4.2 Va Value Parameters of Manufacturing Process of Pasteurized Lassi 24

4.3 Packaging Parameters of Pasteurized Lassi. 25

4.4 Neutritional Facts of Packed Lassi 26

4.5 Parameters for Checking the Shelf Life of packed Lassi 26

4.6 Profit Statement of Pasteurized Lassi 27

LIST OF FIGURES

Figure No. Details of figure Page

No.

3.1 Silos for Storage of Pasteurized Milk 13

3.2 Storage Tank of Lassi 15

3.3 Plate Heat Exchanger 16

3.4 Batch Pasteurizer used in Sudha Dairy 17

3.5 Process Flow Diagram for Mechanized Production of Lassi 18

3.6 Lassi Pouches Discharged on SS tray 19

3.7 FFS Machine 20

4.1 Packed Lassi of Sudha Dairy 25

ABSTRACT

Lassi has a very important influence in the present day market especially in summer

season. It gives high return to the processors and has a numerous of health benefits attributed to

it which includes enrichment of human diet through development of wide diversity of flavours,

aromas and textures of food and help in immune modulation and detoxification during food

fermentation process. The nutritive value of fermented food product like lassi is derived from

nutrients among various metabolites produced by lactic acids bacteria (LAB) during

fermentations besides the nutrients available from milk.

Pasteurized milk standardized to fat 4.6 % and SNF 8.5 % was used for the

manufacturing of Lassi. Starter culture (lactic acid) was added at the rate of 1-2% in order to

bring about acid coagulation of milk and inpart characteristic flavour. The sugar syrup was

prepared separately and added at the rate of 20-25 % of milk volume. Lassi was flavoured with

rose water and the Packaging was done with Form Fill and Seal (FFS) machine in which LLDPE

polyfilms were used. It was packed in pouches of 200ml and the capacity of FFS was 500

pouches per hour. The shelf life of Lassi was assessed through moisture and acidity test and was

found to be 5 days when moisture was 82 % and Total Solid was 18 %. The acidity was found to

be 0.54 %. Cost estimation of pasteurized Lassi of Sudha Diairy was done and sales of Lassi

were found to be very economical.

Keywords: Lassi, Pasteurized milk, SNF, Lactic acid culture, Form Fill and Seal (FFS)

machine, Shelf life, Cost estimation

CHAPTER- 1

INTRODUCTION

CHAPTER- 2

REVIEW OF

LITERATURE

CHAPTER- 3

METHODOLOGY

CHAPTER- 4

FINDINGS

CHAPTER- 5

SUMMARY and

CONCLUSIONS

CHAPTER- 6

SUGSTIONS

CHAPTER- 7

BIBLIOGRAPHY

1

CHAPTER 1

INTRODUCTION

Milk is a complex biological fluid consisting of seven main components: water, fat, protein,

sugar (lactose), minerals, vitamins and enzymes. It could also be described as a true aqueous

solution of lactose, salts and a few other minor compounds, which is emulsified with fat and

supports a colloidal dispersion of proteins. Milk is an almost ideal liquid food universally

accepted for its high nutritive value, flavour and palatability. India is the largest producer of milk

in the world with an annual production of 140 million tonnes. Although India produces the

highest quantity of milk, storing milk is a great problem due to its high perishable nature. It is

very difficult to maintain milk quality at the same level as just after milking. It has been reported

that nearly 5 % of the milk produced in the country goes sour, causing annual loss of Rs. 4,000

crores, which could be easily saved by improving the sanitary condition, cooling and adopting

process technology in dairies. Growth prospects in the dairy sector are bright. India is emerging

as a mega dairy market of the 21st century. The recent liberalization has thrown a bagful of

opportunities for dairy entrepreneurs. Different value added dairy products can be developed

from milk. Lassi is one of them. Out of total production of milk, about 50-55 % is converted into

value added milk products. An estimate of 1% of the country’s total milk production is converted

into Lassi. Lassi has a very important influence in the present day market especially in summer

season. It gives high return to the processors. It is a white to creamy-white viscous liquid with a

sweetish, rich aroma and pleasant mild acidic taste. Lassi has a numerous of health benefits

attributed to it which includes enrichment of human diet through development of wide diversity

of flavours, aromas and textures of food and help in immune modulation and detoxification

during food fermentation process. It preserves food via lactic acids; alcoholic and acetic

2

fermentation reduces cholesterol, restores ecological balance of intestinal flora and acts as a

suppression of pathogens, etc. The nutritive value of fermented food product like Lassi is derived

from nutrients among various metabolites produced by lactic acids bacteria (LAB) during

fermentations besides the nutrients available from milk. Some of the reported nutritional and

physiological benefits of fermented milks are the promotion of growth and digestion, settling

effect of gastro-intestinal tract (GIT) by decreasing harmful bacteria, improving bowel

movement, suppression of cancer and lowering of blood cholesterol. The LAB has also been

used to manage intestinal disorders lactose intolerance, constipation, etc. The chemical

composition of Lassi depends on the type of milk, initial composition of milk, level of

concentration of milk solids and sugar level.

Kumar et al. (1987) have reported that Lassi prepared from the curd obtained when skim milk

and cheese whey which are heated and acidified with HCL and prepared Lassi packed in

polyethylene pouches extended the shelf life by 6 days at 5 0C. Khurana (2006) developed

suitable technologies for the manufacture of mango, banana and pineapple Lassi along

with their low-calorie counterparts using artificial sweeteners. Production of Lassi has been

confined, to a large extent, to the households and local halwais who do not have a standardized

technique for the manufacture of uniform quality Lassi and thus it has a limited shelf life.

Therefore, there is an urgent need of developing a standardized method for the production of

pasteurized Lassi with a uniform quality and extended shelf life. A lactic culture comprising of

Lactococcus lactis subsp. lactis, Lactococcus lactis subsp. cremoris and Lactococcus lactis

subsp. diacetilactis is used for Lassi making in modern process technology. Pasteurized Lassi is

packaged to increase the shelf life of Lassi and prevent further contamination by microorganisms

3

and facilitate for easy handling the product. Keeping above facts in mind, the present project

work was undertaken with the following objectives:

1. To analyze the quality of pasteurized milk

2. To study the manufacture process technology and packaging of Lassi

3. To evaluate the quality and shelf life of packaged Lassi.

4. To estimate the cost of Lassi.

4

CHAPTER 2

REVIEW OF LITERATURE

The development of a product needs intensive and judicious information on various

aspects that can affect the efficiency of the process and the quality of the product. This chapter

deals with the published literature relevant to the present project work on process technology and

packaging of Lassi.

2.1 DEFINATION

Lassi is described as a fermented milk beverage obtained after the growth of selected culture,

usually lactic streptococci, in heat treated or partially whole milk followed by sweetening

with sugar. FAO/WHO (1976) defined Lassi as a coagulated milk product obtained by lactic

acid fermentation of milk through the action of S.salivariussubsp and Thermophilus with or

without addition of whole milk powder or skim milk powder or whey powder. The proximate

composition of Lassi is given below in Table 2.1

Table 2.1 Proximate Composition of Lassi

Milk fat 1.5-3.8 %

Milk Total Solid (TS) 9.00 %

Sugar 13-20 %

Sodium dihydrogenase phosphate (optional) 0.5 %

Low methoxy pectin (optional) 0.5 %

Acidity (minimum) 0.7 %

5

2.2 QUALITY OF PASTURIZED MILK

Pasteurized milk is preferred over raw milk in production of Lassi because it is handled and

stored with great care whereas most of the time raw milk is kept under prolonged exposure to

sunlight which can hamper the quality of Lassi. Marsilli, (1999) reported that a burnt sunlight

flavour is developed during the first 2-3 days of storage and is caused by degradation of sulfur

containing amino acids (methionine) of the whey proteins. Rankins, (2002) reported that milk is

contaminated by E.coli under lack of sanitary conditions which can affect the public health.

Pasteurized milk is used in Lassi making because it provides greater nutritive value as compared

to raw milk. Fromm and Boor, (2004) reported that microbial growth and metabolism shortens

the shelf life of milk and degrades nutritive value by providing undesirable changes in milk

quality. Pasteurized milk with high SSC milk should not be used in Lassi production because it

gives poor keeping quality of milk and milk products. Barbano and Kathyrn, (1991) reported that

pasteurization of raw milk quality with high SCC milk gave poor keeping quality of milk. The

quality of low SCC milk remained high even 21 days after processing under refrigerated storage.

Azzara and Dimick, (1985) reported that pasteurized milk containing high SCC showed

significant sensory defects, which included rancidity, bitterness, and astringency and causes

decrease in sensory quality of high SCC milk. It is often said that pasteurization of milk leads to

loss fat soluble vitamins and the products obtained from pasteurized milks ate not nutritive but

this is not true. Lejeune and Schultz, (2006) reported that there is no real loss of fat soluble

vitamins with pasteurization (vitamin A, D, E, and K). It is a myth that enzymes present in cow’s

milk acts as enzymes in our body and during pasteurization, these enzymes are destroyed and

therefore pasteurized milk should be preferred for producing milk products. Miller, (2007)

reported that most enzymes survive pasteurization intact and like other proteins, these enzymes

6

are digested in our body and even though if these enzymes survive they are not used as enzymes

in our body. Torkar and Teger, (2008) reported that production of high quality of liquid milk

product is dependent upon the microbiological quality of milk; hence, use of pasteurized milk is

often preferred over raw milk. The bacterial count in pasteurized milk is lower, that is why it is

preferred in Lassi manufacturing as compared to raw milk. Adil, (2013) reported that the range

of stphylococci counts in milk samples of pasteurized milk were less than that of raw milk.

2.3 Processing and Packaging of Lassi

In recent years, there is a considerable increase in the consumption of cultured dairy products

especially Lassi which could be ascribed to its wholesomeness in terms of nutritional and

therapeutic properties Shahani and Chandan, (1979) reported that the starter cultures used in

cultured dairy products bring about changes in physico-chemical characteristics besides

enhancing the nutritional value of the resultant product. Lassi can be prepared by using curd

obtained from skim milk. Kumar et al. (1987) have reported that Lassi can be prepared from the

curd obtained when skim milk and cheese whey are heated and acidified with HCL. The

inadequate packaging and improper refrigeration results in low quality of Lassi. Rankin, (2002)

reported that improper refrigeration, low quality raw material and an inadequate packaging

system caused problem in maintenance of quality of value added products like Lassi which is a

great problem in many countries. Lassi is commonly flavoured with rose water but if it is

flavoured with pineapple then the colour, appearance and taste is comparatively better than that

of rose water. Sanjay et al. (2008) reported that Instant Lassi prepared from cow milk

standardized to 4 % and SNF 8.5 % and adjusted to pH 3.8 and 12 % sugar had no influence in

colour, appearance or overall acceptability and instant Lassi flavored with pineapple was best in

colour, appearance and acceptability. Lassi can also be prepared using paneer whey and buffalo

7

milk with pectin and CMC as stabilizers. Mittal, (2003) reported the development of Lassi using

paneer whey and buffalo milk with fat 6.5 % and pectin and CMC used as stabilizers and

concluded that the product with 70 % whey and pectin CMC in the ratio 0.5:1 and 0.6 % level

were adjudged most acceptable. Milk containing butter whey is used in preparation of Lassi in

some of the countries to utilize the byproducts in a profitable manner. Deka et al. (1984) reported

the production of Lassi using milk containing whey and buttermilk and the blanched soyabean to

make slurry of soyasolids – buttermilk solids. Industrial process with mechanization is developed

for manufacture of Lassi. Various types of technologies are available for the preparation of

various flavours of Lassi. Khurana (2006) developed suitable technologies for the

manufacture of mango, banana and pineapple Lassi along with their low-calorie counterparts

using artificial sweeteners.

Packaging is a gateway to know a product. A product is often identified by the package in which

it is served. Packaging forms an integral part of food production, marketing and distribution.

Development of suitable packaging systems is essential for modernization of the traditional dairy

products industry. Skibsted (2000) reported that packaging is an integral part of product

processing and operations and offers effective protection to the product. Robertson (2006)

reported that packaging serves a number of different functions including protection, convenience

and communication most important being protection. Other than the primary functions, there are

several secondary functions of packaging. Paine (1996) reported that in addition to the primary

functions of packaging, an effective packaging system must fulfill other requirements like

compatibility with dairy products. It contains recyclability, aesthetics, machinability and

functionability in terms of shape size and disposability. Flexible packaging films are normally

considered as a packaging material and LLDPE (Low linear density polyetylene) is one of them.

8

It is a tough and translucent to opaque waxy material. It has good impact strength at low

temperature and has low moisture permeability, but its oxygen permeability is relatively high. By

incorporating pigmented colour, this packaging material can provide barriers to light. Deman

(1981) studied the vitamin content of product packed in LLDPE pouches of before and after

exposure to 2200- lux-intensity and reported that fluorescent light retain upto 48 hour at

refrigeration temperature.

2.3 Quality and Shelf Life of Lassi

The shelf life of Lassi largely depends upon the standardization technique of manufacturing of

Lassi. Sanjay et al (2008) reported that Instant Lassi prepared from cow milk standardized to

4% and SNF 8.5% and adjusted to pH 3.8 and 12% sugar had no influence in colour,

appearance or overall acceptability and instant Lassi flavored with pineapple was best in

colour, appearance and acceptability. Naresh and Prasad (1996) reported that Lassi prepared

by adding Nicin at the rate of 200 IU/ml at 20 0C increased shelf life upto 48 hours and by

adding Nicin at the rate of 500 IU/ml extended shelf life up to 8-10 days at refrigerated

temperature. Lassi prepared and packed in polythene pouches also extends shelf life. Kumar et

al. (1987) have reported that Lassi prepared from the curd obtained when skim milk and

cheese whey which are heated and acidified with HCL and prepared Lassi packed in

polyethylene pouches extended the shelf life by 6 days at 50C Deka et al. (1984) reported

preparation of Lassi with slurry of buttermilk and soyabean cotyledons and packed in

polythene pouches extended the shelf life by 10 days when stored at 50 C. Extension of shelf

life of Lassi can be achieved by UHT treatment and asceptic packaging. Aneja et al. (1989)

reported the extension of shelf life of Lassi is achieved by ultra high temperature

(UHT) processing of product after fermentation and packaging it aseptically. Starter

9

culture brings about acid coagulation of milk and imparts characteristic flavour and also

increases its shelf life. Chandan, (1995) reported that starter culture brings about physio-

chemical changes in Lassi and also extends the shelf life of Lassi at 4 0C. The shelf life of

Lassi can be increased by addition of antibacterial agents. Gaikwad and Hambade (2013)

reported that potassium sorbate added products gave shelf life upto 20 days at refrigerated

temperatures and 10 days at ambient temperatures (30 0C) Addition of LAB increases the shelf

life of Lassi. Ganguly (2001) reported that LAB shows remarkable antimicrobial activity

against pathogens and spoilage microorganisms. Akin and Guler (2005) reported that lactic

acid and acetic acid content in product affects the viability of probiotic bacteria in food.

Fedala et al. (2009) reported that rate of acidification depends on amount and type of starter

culture which will affect the shelf life and quality evaluation of fermented product like Lassi.

2.4 Cost Estimation of Lassi

The production cost of pasteurized Lassi alone is not estimated but an overall cost of each unit

operation is involved to estimate the total cost of pasteurized Lassi. Barlett, (1952) reported that

cost for various operation of a pasteurizing plant involves pasteurization cost, material cost,

handling cost, procurement cost, processing cost and packaging cost. Cost of production from the

plant depends upon the plant capacity. Strain and Christenson, (1960) surveyed in plant cost of

processing fluid milk and milk products in Oregon in 1956 to determine the relationship between

cost and plant size. They reported that as the plant size and capacity is increase the cost of

producing decreases which shows that with an increase in capacity of production, cost of

producing will decrease and a higher profit will be earned.

The overall cost in estimating the production of Lassi involves cost of raw material which

includes procurement of raw material. Belloin, (1988) reported that fat and SNF losses were

10

worked out by dividing the fat loss during processing with the fat content before processing and

the equivalent amount of loss was included in the raw material cost. Other than raw material cost

of labor is another factor affecting the overall cost estimation. Labor cost involves one-third of

the total in plant costs. The labor requirement and utilization may be expressed in terms of

product handled per hour or day of labor. Strain and Christenson, (1960) reported that an

efficiently operated plant in the United States producing several fluid products will process from

200-300 quintal equivalent of product per man hour of labor.

11

CHAPTER 3

METHODOLOGY

This chapter deals with the material used and the techniques adopted for carrying out

the experiments to achieve the objectives of project. The chapter includes the experimental site

of project work, quality evaluation of pasteurized milk, manufacturing process technology and

packaging of Lassi, evaluation of shelf life of Lassi and evaluation of the cost of pasteurized

Lassi.

3.1 Experimental Site : The project work was carried out at Sudha Dairy plant situated at HEC

Campus, Dhurwa, Ranchi (Co-operative Milk Producer Federation Ltd, Patna) which was

established in 1990-1991 and it has a capacity of 1,20,000 liters of milk per day.

3.2 Quality Evaluation of Pasteurized Milk

Milk which was pasteurized in the H.T.S.T plant of Sudha Dairy was used in the manufacturing

process of Lassi. The quality of pasteurized milk was evaluated through the MBRT (Methylene

Blue Reduction Test). The principle of M.B.R.T depends on the fact that the colour imparted to

the milk by adding methylene blue dye will disappear more or less quickly, which depends on

the quality of the milk to be examined. Methylene blue is a redox indicator, that lose its colour

under the absence of oxygen and is thought to be reduced. The depletion of oxygen in the milk is

due to the production of reducing substances in the milk due to enhanced rate of bacterial

metabolism. Colour of the incubated test tube was observed at an every half an hour interval and

when it changed to white the interval was noted.

Equipments used in were test tubes, rubber cork, water bath and burner.

12

The test was performed by taking 10 ml of milk in a test tube and 1 ml of methylene blue

indicator was added to the test tube. Mouth of the test tube was closed with a rubber cork and

incubated in water at temperature 37 0C. The quality rating of milk in M.B.R.T is given in Table

3.1

Table 3.1 Quality Rating used in M.B.R.T

M.B.R.T (hours) Quality of milk

5 and above Very good

3 and 4 Good

1 and 2 Fair

½ and below Poor

3.3 Manufacturing Process of Lassi

The pasteurized milk was used for manufacturing of Lassi and the milk was stored in Silos. The

plant had six silos for storage of pasteurized milk with the capacity depicted in Table 3.1 and Fig

3.1 showing one of the silos present in Sudha Dairy for storing of pasteurized milk.

Table 3.1 Capacity of Silos.

Silos Capacity (liters)

S1 and S2 30,000

S3 and S4 40,000

S5 29,000

S6 and S7 60,000

13

Fig. 3.1 Silos for Storage of Pasteurized Milk

The milk was here standardized to fat 4.6 % by adding white butter and SNF 8.5 % by adding

skim milk powder.

The calculation for standardization of milk is show below:

For standardization of milk, skim milk powder and white butter were used

Milk volume having fat content of 3.2 % and solid not fat (SNF) of 8.3 % = 15000 kg

Amount of Fat in milk = 3.2 % of 15000 kg

= 480 kg

During standardization of milk the fat content of milk was increased from 3.2% to 4.5 %

Hence amount of fat in milk having 4.5 % fat = 4.5% of 15000 kg

= 675 kg

14

Amount of fat added = 675- 480

= 195 kg

Since white butter was used for increasing fat content of milk and white butter contained 82 %

fat, hence actual amount of white butter required = 195/ 0.82

= 243.75 = 244 kg

Similarly, Amount of SNF in milk before standardization = 8.3 % of 15000 kg

= 1245 kg

During standardization of milk the SNF content of milk was increased from 8.3 % to 8.5 %

Hence amount of SNF in milk having 8.3 % SNF = 8.3 % of 15000 kg

=1275 kg

Amount of SNF added = 1275- 1245 = 30 kg

Since SNF was used in the form of skim milk powder having SNF of 96 % hence, actual amount

of skim milk powder required = 30/0.96

= 31.54 kg

= 32 kg

The actual amount of white butter and skim milk powder used during standardization of milk

were 250 kg and 35 kg respectively from safety point of view.

15

The standardized milk was then transferred to manufacturing unit of Lassi. Here there were two

storage tanks each having a capacity of 1500 liters. The storage tank used in Sudha Dairy is

shown in Fig. 3. 2

Fig.3.2 Storage Tank of Lassi

The standardized milk in the storage was used for manufacturing of Lassi. The manufacturing of

Lassi was started by heating milk to 80 0C and then cooled to room temperature (37-40

0C). Plate

heat exchanger was used in this process. It had metal plates to transfer heat and chilled water for

cooling which is shown in Fig. 3.3

16

Fig. 3.3 Plate Heat Exchanger

After this there was addition of starter culture at the rate of 1-2% and was left for 3 hours for

setting up of curd. The basic role of starter culture was to bring about acid coagulation of milk

and impart characteristic flavour. The culture was pure, active and free from gas producing

microorganism. Lactic culture comprising of Lactococcus lactis subsp. lactis, Lactococcus lactis

subsp. cremoris and Lactococcus lactis subsp. diacetilactis was used for Lassi making. Setting of

milk was terminated at an acidity of 0.70 – 0.80 % lactic acid. In the set curd sugar syrup was

added which required sufficient heat treatment (80-90 0C) to prevent microbial contamination

through sugar. Batch pasteurization was used for heating for 35-40 minutes (shown in Fig. 3.5).

17

.

Fig 3.4 Batch Pasteurizer used in Sudha Dairy

Curd was broken by stirring and sugar at the rate of 20% of that of milk was dissolved in water

and was added in the form of syrup which had been pasteurized at 80 0C and cooled to 55-40

0C

separately. It was also essential to cool the syrup to room temperature before addition to Lassi to

prevent hardening of fine curd particles and whey separation. After the setting up of curd agitator

was switched on for mixing up of milk and culture. Smooth consistency of Lassi was obtained by

homogenization of the mix. Homogenization prevents cluster formation, rising of fat to the

surface and improves consistency. Dual homogenizer was used in Sudha Dairy having pressure

500 PSI and 2500 PSI (shown in Fig. 3.6) The flavour was added before packaging at the rate of

0.6 ml per liter of milk. Lassi prepared was then transferred to packaging machine. The flow

diagram for the manufacturing process of Lassi is depicted in Fig. 3.5

18

Fig. 3.5 Process Flow Diagram for Mechanized Production of Lassi

Standardized milk

Heating

Cooling to room temperature sugar syrup

Culture Inoculation of culture

Heating

Breaking of curd

Cooling Addition of sugar Filtration Addition of flavour Homogenization

Cooling

Storage

Packaging

Crating

Storage

Dispatch

19

3.4 LASSI PACKAGING SYSTEM

3.4.1 The film used for packaging of Lassi was LLDPE (Linear Low Density Polyethylene)

It was a pillow-shaped pouch (also referred to as sachets) for fluid packaging. LLDPE was

preferred resin for pouches as it possesses high melt strength, excellent seal integrity, and

toughness to withstand tears and pinholes. The pouch material was pigmented to reduce light

transmission. There was a combination of two pouches used: an outer one made of LDPE and an

inner one made of LLDPE. The double-ply structure was used to avoid leakage. Lassi was filled

in 60-80micron LLDPE coextruded pillow type pouches and the pouches were discharged on SS

tray and manually filled in plastic crates moving on a conveyer which is shown in Fig. 3.4 Pouch

size for 200ml sachet was 8 cm long and 14 cm wide.

Fig. 3.6 Lassi pouches discharged on SS tray

20

3.4.2 Sachet Form fill machine was used for packaging of Lassi.

A simple cheap form of container for Lassi is the pouch. Heat sealable plastic film is used which

is fed continuously from a roll. The container material used moves continuously downward in a

strip, the film is folded longitudinally and the edges heat sealed to make a flat vertical tube. As

the continuous cylinder moves downwards, transverse heat seals are made by jaws which have

the effect of closing the bottom of pouch, so that measured volumes of liquid product can be

filled into the space above a seal. A further seal above the liquid produces a pillow shaped

flexible pouch or sachet which can be separated from the tube as an individual pack. The liquid

milk dosing in the liquid filling machine is based on the electronic time based digital circuit. The

filling machine consists of a constant level tank with special float valve to maintain a constant

head of liquid to be filled. After the requisite signal is received, the dispensing valve opens to

allow the flow of liquid for a particular preset time. The flow of liquid through this valve is

directly proportional to time for which it is kept open because it is flowing against constant heat

(by gravity). In Fig. 3.5 the FFS machine used in Sudha Dairy is shown. The packed Lassi was

then stored in refrigeration condition at 40C.

Fig. 3.7 FFS machine

21

3.5 Quality and Shelf Life of Lassi

The shelf life of Lassi largely depends upon the standardization technique of manufacture of Lassi

and also on the packaging system and packaging material used. The shelf life of packaged Lassi

was assessed through moisture and acidity test.

3.5.1 MOISTURE AND T.S OF LASSI

An aluminum dish weighted 14.2g was taken into which dried sample of Lassi weighted g was

taken luminum dish with sample taken were kept in hot air oven and maintained at temperature

- for hours he aluminum dish was cooled after 2 hours. The percentage TS was

calculated using the following equation.

% TS = (Weight of dried sample /Weight of sample taken) 100

% of moisture = 100 – TS%

3.5.2 ACIDITY TEST OF LASSI

10g Weighted sample of Lassi was taken in dry and clean beaker and 10ml of distilled water

was added to make solution of sample after which 2 drops of phenopthalin indicator was added

and titrated with (N) NaOH and was titrated till the colour of the sample of Lassi changed to

pink. The % acidity was calculated with the following equation.

Acidity = Volume of NaOH consumed 0.9

22

3.6 Estimation of Cost of Pasteurized Lassi

A cost estimate is the approximation of the cost of a program, project, or operation. The cost

estimate is the product of the cost estimating process and has a single total value and may have

identifiable component values. The estimation of cost of Lassi was done from the main

department and the auxiliary department. The main department was directly related to the

manufacturing process of the dairy products and was related to the direct cost involved in

manufacturing whereas auxiliary department provides services to support the manufacturing

process like steam generation, refrigeration, water supply, maintenance, fuel etc. or in other

words it is indirectly related to the cost involved in manufacturing (indirect cost). With the help

of direct and indirect cost, realization or sales value was done which was also called operating

revenue. After getting an operating revenue operating cost or operating expense in Lassi

processing was calculated which include raw material cost (i.e. cost of raw material, curd culture

sugar), procurement cost, processing cost (which include cost of machine, electricity, water

supply, etc.), packaging cost (which include cost of ink used and machine), selling and

distribution cost (which include transportation cost, cost of crates used in transportation, storage

cost) and handling loss during processing. Operating profit was calculated by subtracting

operating expense from operating revenue. Operating profit helps in continuous processing of

milk. Further depreciation on machines (depreciation of machine usually gives an estimate of

economics of dairy plant operation), non-operating income (which include interest other than

business like interest on FD, scrap value etc.), trading item profit (which was taken from records)

were subtracted from operating profit to get Net profit for milk production.

23

CHAPTER 4

FINDINGS

This chapter deals with the findings related to the quality of pasteurized milk,

manufacturing and packaging of Lassi, evaluation of its shelf life and estimating the cost of

packed Lassi at Sudha Dairy.

4.1 Quality of Pasteurized Milk

The quality of pasteurized milk was analyzed through M.B.R.T test and the M.B.R.T of

the pasteurized milk was found to be 6 hours. The observations related to quality of

pasteurized milk are shown in Table 4.1

Table 4.1 Quality Parameters of Pasteurized Milk

Quality Parameters Observations

pH 5.5

M.B.R.T 6 hours

Fat % 3.2

SNF % 8.3

Water % 87

Carbohydrate % 4.9

Protein % 2.5

Analyzing the quality of pasteurized milk was important because it gave the present parameters

related to the quality of milk which was important for manufacturing of Lassi. Milk was not

accepted if the M.B.R.T hours were less than 5 hours as it would affect the quality of Lassi. The

24

other parameters like Fat and SNF were found to be 3.2 and 8.3 % respectively which were

further standardized to 4.6 and 8.5 % respectively for manufacturing of Lassi.

4.2 Processing and Packaging of Lassi

The value parameters of process manufacturing were studied and noted which is shown below

in Table 4.2

Table 4.2 Value parameters of Manufacturing Process of Pasteurized Lassi

Observation Value of Parameters

Standardized milk Fat- 4. 6% and SNF 8.5 %

Heating milk temperature 82 0C

Time of heating milk 15-20 seconds

Cooling milk temperature 37 0C

Culture used Lactic acid

Inoculation culture rate 1-2 %

Breaking curd acidity 0.4-0.6 % L.A

Sugar syrup heating temperature 82 0C

Sugar syrup heating time 35-40 minutes

Cooling temperature 55-40 0C

Amount of Sugar added 20-25 % of milk volume

Amount of Flavour added 0.6 ml/ l of milk

Type of Flavour used Rose water

It was observed that standardized milk was used for manufactiring of lassi and Lactic acid

culture was used at the rate of 1-2 % for breaking of curd with acidity 0.4-0.6 % acidity and

25

sugar syrup was added. The Pasteurized Lassi was flavoured with rose water before packaging

and then transfereed to packaging system. Figure 4.1 shows the packed Lassi of Sudha Dairy.

Fig.4.1 Packed Lassi of Sudha Dairy

4.2.1 Packaging process of Lassi

After processing Lassi was packed several parameters were noted which is given in Table 4.3

Table 4.3 Packaging Parameters of Pasteurized Lassi.

Packaging machine used Form fill seal (FFS) machine

Type of film used Linear density polyethylene (LLDPE)

Type of packaging Pouches in multi layer carton

Temperature at which Lassi is packed 5 0C

Size of pouch 200ml

Capacity of packaging machine 500 pouches per hour/ 24000 pouches per day

The material used for packaging was LLDPE which is most widely used plastic over dispensing

bottles or wash bottles. Packaging was done through FFS machine and all parameters were set

before starting the machine.

26

4.2.2 Nutritional Facts of Packed Lassi

The packed Lassi manufactured in Sudha Dairy is nutritious and also provides energy on its

consumption. Table 4.4 depicts the nutritious facts of Lassi manufactured by Sudha Dairy.

Table 4.4 Neutritional Facts of Packed Lassi

Neutritional Facts per 100 ml Value

Energy 102 Kcal

Can Sugar 14.0 g

Lactose 2.8 g

Protein 2.5 g

Fat 2.8 g

4.3 Quality and Shelf Life of Lassi

After the Lassi was packed the quality of packed Lassi was rechecked by for evaluating its Shelf

Life and the observations recorded is given in Table 4.5

Table 4.5 Parameters for checking the Shelf Life of packed Lassi

Observations Scale of Parameters

Total Solid 18 %

Moisture 82 %

Acidity 0.54 %

Shelf Life 5 days

The packed Lassi was evaluated for Moisture, TS and acidity test in order to note the shelf life

period which was 5 days when moisture was 82 % and TS was 18 %.

27

4.5 Cost Estimation Data for Pasteurized Lassi

Cost data for Pasteurized Lassi was taken from the Accounts Department for the month of June,

2014 and profit was calculated as shown in the table below in Table 4.6

Table 4.6 Profit statement of Pasteurized Lassi

Details Lassi (Rs per unit in liters)

Realization

Material cost

Handling loss

Procurement cost

Processing cost

Packing cost

Selling distribution cost

Administrative cost

Total cost

Operating profit

Depreciation

Trading item profit

Net profit

12.34

5.42

0.02

0.15

0.14

0.34

0.04

0.16

6.27

6.07

0.03

0.01

6.05

Realization is sales value estimated for the production process, operating profit is that part of

profit which was required for continuous processing. It was observed that manufacturing of Lassi

was very economical as it gave nearly 49 % of profit in its marketing. There was a very minute

handling loss involved and per day sale of Lassi were 10263 pouches which show that it has high

demand in market, therefore, manufacturing of Lassi was found to be very economical.

28

CHAPTER 5

SUMMARY AND CONCLUSIONS

Sudha Dairy is well equipped with all the necessary automatic machines in its plant for various

processes from pasteurization of milk to production of various value added products. The dairy

produces pasteurized Lassi which has a greater nutritive value.

Milk is an almost ideal liquid food universally accepted for its high nutritive value, flavour and

palatability. India is the largest producer of milk but then storing is a problem due to its shorter

shelf life. But the recent liberalization has thrown a bagful of opportunities for dairy

entrepreneurs and different value added dairy products are being developed from milk. Lassi is

one of them. n estimate of % of the country’s total milk production is converted into Lassi. .

Pasteurized milk are preferred over raw milk in production of Lassi because it is handled and

stored with great care whereas most of the time raw milk is kept prolonged exposure to sunlight

which can hamper the quality if Lassi The method of manufacture of Lassi involved

standardization of milk, heating and cooling of milk to inoculation temperature, addition of

starter culture and setting of milk. Sugar @ 12-15% of milk dissolved in equal quantity of water

was added in the form of syrup which was pasteurized and cooled separately and then

homogenized for getting smooth consistency of Lassi and then it was sent to packaging section

for packaging using Form Fill Seal Machine in which LLDPE films were used as a packaging

material. Moisture and acidity test was done for evaluating the quality and shelf life of packed

Lassi after which they were stored in refrigerated temperature of 40C under vapour compression

refrigeration temperature.

29

Based on results obtained, the following conclusions have been drawn in the present project

work:

1. Pasteurized milk was used for manufacturing of Lassi so that there was no microbial

contamination and was free from mastitis milk, lipolytic rancidity, residual antibiotics

and germicides.

2. The culture used in manufacturing of Lassi was pure, active and free from gas producing

microorganisms. Sugar syrup was pasteurized and then added so that it was free from ay

contamination.

3. Packaging of pasteurized Lassi was effective as it added value and standard level to it

which was mostly accepted by all consumers and increased the shelf life of Lassi.

LLDPE polyfilm was used for packaging which provided barrier from lights and had low

moisture permeability and high oxygen permeability.

4. Further the quality of pasteurized Lassi was evaluated through moisture and acidity test

which was found to be effective as it indicated the present microbial status of pasteurized

Lassi and thereby indicating its shelf life which was upto 5 days under refrigeration

condition.

5. Cost estimation process was found to be effective as it indicated the profit percentage of

pasteurized Lassi.

30

CHAPTER 6

SUGGESTIONS

There is lack of proper sanitation and lighting in the plant, hence there is a need of an good

manufacturing practice for better quality of products.

The raw material handling and regular manufacturing process needs to be regularly

monitored to prevent contamination of end products.

The organization needs to hire skilled personals to enhance efficiency of plant.

Adoption of Technical developments is also needed in the organization for further extension

of enhance shelf life of Lassi which can be achieved by UHT (Ultra Heat Technology)

processing of Lassi after fermentation and packaging aseptically.

Significant innovations like Aseptic packaging and Use of advancement in the manufacturing

process like using of directly acidified milk beverage can lead to extension of shelf life Lassi

by 120 days.

31

CHAPTER 7

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