A review on mechanization of traditional dairy products

Indian J Dairy Sci 70(1), 2017

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REVIEW ARTICLE

A review on mechanization of traditional dairy products

Gopika Talwar and Sandeep Pal Kaur Brar

Received : 14 April 2016 / Accepted: 20 December 2016

Gopika Talwar1() and Sandeeppal Kaur Brar2

1 Dairy Engineering, College of Dairy Science and Technology, GADVASU,Ludhiana , Punjab2College of Dairy Science and Technology, GADVASU, Ludhiana, Punjab.

Gopika TalwarDairy EngineeringCollege of Dairy Science and Technology,GADVASU, Ludhiana , PunjabEmail: [email protected]: +9876578765

Abstract: India is the largest milk producing nation in the world.Milk is perishable in nature, thus it cannot be stored for a verylong period. In order to preserve it, more than half of milkproduced in India is converted into a variety of traditional valueadded milk products which played a significant role in the Indianeconomy. Traditional milk products have a distinct advantage ofbeing value added products, mass appeal, give high profit marginsand have high export potential. Indian traditional dairy productsare largely classified into 5 broad categories i.e. Heat desiccatedproducts, acid coagulated, cultured or fermented, fat rich andmilk based deserts . Increasing demand for these products in Indiaas well as global market present a great opportunity for theorganized dairies in the country to modernize and scale-up theproduction. There has been significant development andmechanization in dairy sector in past few years. It has transformedvarious processes for dairy products from traditional energy andlabour intensive processes to mechanized processes where humaninterference is minimized. In this article various researches andadoptions done for mechanization of various dairy processes isreviewed. This will help in knowing products wheremechanization has taken place and will help researchers to targetwhere mechanization is further required and also helpentrepreneurs to upgrade themselves from traditional system toavailable mechanized system.

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

Introduction

In Indian economy, there has been significant development indairy sector in past decade. Today, India is the largest producerof the milk and value added milk products in the world accountingfor more than 16% of worlds total milk production. The totalmilk production in India is over 132 million tonnes. Milkproduction 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 isconsumed as liquid milk, the increase in consumption can bestimulated. Milk plays an important role in the national diet as itis consumed in liquid form as well as value added products likeDahi, Paneer, Butter, and sweets. Also milk can be preserved forlonger period by converting significant proportion of milk into awide variety of dairy delicacies. It is estimated that 50 to 55 percent of the milk produced in India is converted into a variety oftraditional milk products, using processes such as coagulation(heat and/or acid), desiccation and fermentation. The market forIndian milk products is estimated to be 10 billion US dollar(www.niir.org). This fact underlines the significance of Indianmilk products in the national economy. Over the millennia, theprocesses and technologies for manufacture of value added dairyproducts have undergone a change. It has transformed fromtraditional energy and labour intensive processes to mechanizedprocesses where human interference is reduced. Mechanizationprovides many advantages like uniform quality and less use oflabour, less spoilage etc. Some of the technologies andmechanized processes have been adopted by organized orunorganized sector. It is important to review the traditionalprocesses in comparison to new processes to study the impact ofmechanization in different categories of dairy productmanufacture. Recently a few organised dairy sectors have madeattempts to develop batch, semi continuous, and continuousequipments for production of traditional dairy products on acommercial scale. While many new innovations have taken placerecently to modernize this sector, but have not percolated to theactual users. Hence, it is necessary to look into short, mediumand long term strategies to develop core technological strengthsfor envisioning a developed indigenous dairy products sector. Tojudge the extent of mechanization in dairy sector it is important


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to know the different processes and technologies that have comeup in dairy sector.

Recent advancements in mechanized manufacturing of traditionaldairy products

The making of traditional dairy products has essentially been acottage scale enterprise. Although information available on theseproducts is inadequate, an effort has been made to focus on theirtechnologies, including their preparation, physic-chemicalattributes, shelf life behaviour, packaging and the like. In thissection, the technological aspects of wide range of Indian dairyproducts that are largely followed or are under development, arepresented under five broad categories, listed below:

Heat desiccated milk based products

Heat and acid coagulated products

Cultured/Fermented products

Fat rich products

Milk based puddings/Desserts

Heat desiccated milk based products:

Heat desiccated milk products are those products which areprepared by heat desiccation of milk and by subsequently addingsugar in to it. Khoa, an intermediate base for a wide range ofsweets such as Gulabjamun, Burfi, Peda, Kalakand, Rabri, Kulfietc. is a good example of heat desiccated product. The heatprocessing and accompany reduction in water activity result insubstantial destruction of pathogenic and spoilage microorganisms as well as inactivation of enzymes. Besides, desirableheat induced chemical interactions among milk constituents resultin reduction of redox potential and water activity which extendthe product shelf life. Besides these desirable flavours, textureand overall acceptability of the product is enhanced by heatprocessing. During desiccation whey proteins are almost fullydenatured from colloidal state of non-dispersible state. The factorsthat influence the heat coagulation are temperature and time ofholding, concentration of casein, acidity of milk, salt balance andprecise heat treatment. The colour of milk changes from light toa more intense shade of the colour due to denaturation andcoagulation of protein. Due to vigorous agitation of milk at hightemperature the fat globules are appreciably sub-divided. Almosthalf of the globular fat is released as free fat-the extent of whichdepends upon the type and fat content of milk and manufacturingprocess. Usually 44.8 to 62.8 % of fat appears as free fat in khoa.

Khoa

The traditional method for preparing khoa utilizes simple utensilsand direct smoke-free fire for desiccation. Typically, 4 to 6 litre

lots of milk are taken in shallow iron/mild steel pan and simmeredover direct non-smoky fire with constant and vigorous stirringand occasional scrapping of the heating surface to avoid buildingof scale/scorching. After some time of rapid evaporation, whenconcentration of about 2.5 to 3 times has been attained, coagulatedparticles are brought together with the stirrer and compacted as asemi-solid mass.

As heating continuous further with constant agitation andscrapping of the heating surface, free fat oozes out. From thisstage, subsequent heating has a pronounced effect on thedevelopment of typical khoa flavour and texture. Since colourtends 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 thepan, spread uniformly over trays and allowed to cool underatmospheric conditions.

This method is labour and energy intensive and the end productvaries in quality from batch to batch. Further, the microbiologicalquality of the product is susceptible to environmental influencesdue to desiccation under open atmospheric conditions. The needwas felt to develop a design for mechanised production andpackaging of khoa. Several researches have been made tomechanize the process for large scale manufacture of khoa in thecommercial sector. The first attempt to develop prototype ormechanized production of khoa was made in the 1960’s at theNational Dairy Research Institute (NDRI), Karnal.

A semi continuous khoa making machine was first developed byBanerjee et al ;1968 and its subsequent modification was doneby De and Singh (1970). The equipment comprised of a scrapedsurface heat exchanger (for pre-concentration of milk) and twoopen semi jacketed steamed pan with mechanical scraper agitators(for final concentration of milk). This equipment was quitesuitable to replace traditional appliances for cottage scaleoperation but was too bulky and the product was lacking inorganoleptic quality.

Sawhney et al ;1980 followed by More ,1987 designed batchtype semi-continuous mechanized scrap surface heat exchangerby providing steam jacketed pan and scraper assembly. This wasgood attempt for production of khoa under rural conditions butfound unsuitable on commercial scale.

For efficient use of thermal energy and less heat, Agarwala et al; 1987 developed a mechanized conical vat for preparation ofkhoa. A prototype of khoa making machine consisted of ahorizontal cylinder of mild steel having a steam jacket on thelower half side was developed (Christie and Shah, 1988). Inspiredby the performance of this prototype machine, another batch typemachine of stainless steel with power drive was developed byChristie and Shah, 1990.


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The use of horizontal thin film SSHE was reported for continuouskhoa production (Abichandani and Sarma, 1985). A correlationwas developed for power requirement to drive the rotor for astraight sided thin film SSHE by taking water as a working fluid(Abichandani and Sarma, 1988). Thin film SSHE application wasextended for concentration of milk to high solids and its suitabilityfor continuous khoa production was confirmed (Dodeja et al ;1990). The performance of thin film SSHE was evaluated atdifferent rotor speeds and steam temperatures for continuousmanufacture of khoa (Dodeja et al ; 1990).

National Dairy Development Board has developed an inclinedscraped surface heat exchanger (ISSHE) was developed tomanufacture khoa continuously (Punjrath et al ; 1990).

The heat exchanger comprises of inner cylinder, rotor drive andouter steam jacket. In this system the scraper repeats the processof moving coagulated particles from heat transfer surface andmixing them back to pool of liquid. The angle of inclination ofISSHE permits the formation of pool of boiling milk critical forformation of khoa.

Rajorhia et al 1991 compared the quality of khoa prepared viz;ISSHE, convap-contherm conical vat and roller drier with regardsto physic-chemical characteristic, sensory properties, rheologicalproperties and operational features. It was concluded that amongthe selected systems inclined surface heat exchanger (ISSHE)proved to be the most appropriate for continuous manufacturingof khoa.

The effects of various parameters on evaporation of water,concentration of milk, and dehydration of cream in straight sidedhorizontal thin film SSHE was reported (Abchandani and Sarma,1991). A thin film SSHE system of mild steel for continuousmanufacturing of khoa by arranging two SSHE in a cascadefashion was developed (Dodeja et al ; 1992). Later on, the qualityof khoa obtained from this machine was attempted to improve byadding a third stage with modified rotor blade assembly (Kumaret al ; 2009). A continuous khoa making unit of mild steel wasdeveloped by arranging three identical SSHE one over anotherto control the product flow under gravity (Bhadania et al ; 2005).

In Industrial production of khoa, energy conservation is animportant consideration. Concentration of milk in an open pan isenergy intensive and uniformly smooth khoa is required to impartthe desirable texture to the finished product as it emerges fromthe SSHE. Keeping in view these aspects, the first attempt toapply pressure driven membrane separation process of reverseosmosis has been successfully tried by Pal and Cheryan, 1987.The utilization of solar energy in dehydration of milk for themanufacture of khoa was attempted, and reported that solarmethod of dehydration results in less evaporation of water frommilk (Dande et al ; 2011). A 3-stage SSHE for manufacture ofkhoa was developed (Dodeja and Deep, 2012) and the quality of

khoa manufactured from SSHE was claimed to be comparablewith the market samples.

Khoa based sweets

Successful attempts have also been made to mechanize the processfor manufacturing of khoa based sweets.

A mechanized process for commercial production of burfi wassuccessfully developed by (Palit and Pal, 1998) at NDRI. Theprocess involved the continuous khoa making from SSHE/TSSHEfollowed by kneading and heating khoa sugar mixture in Stephenkettle for uniform blending. Later on there was development ofa three stage burfi making system for the continuousmanufacturing of burfi but industrial trials indicated accumulationof product inside SSHE causing non-uniform flow due to improperexpelling action. In order to overcome the drawback of existingrotor blade assembly a new rotor blade assembly was fabricatedby providing a combination of flat blades and skewed blades(Kunju and Dodeja, 2004). Better quality and minimumaccumulation of product was obtained at maximum rpm andmaximum skewed blade angle.

Peda

Peda is an indigenous milk product, prepared by mixing khoawith copious quantities of sugar. Patel (1986) reported that pedacan be prepared with 5 liters milk taken in a pan as a batch andby adding 450 g of sugar to boiling milk and subsequentlyfollowing traditional method. Many workers have studied differentmethods to modify the process of peda making. Reddy (1985)followed by Mane (1994) developed a process for preparation ofplain peda using skim milk powder (SMP). Deewani andJayapraksha (2002) made use of whey protein concentrate (WPC)in preparation of peda and found that sensory characteristics canbe enhanced by increasing level of WPC up to 40%. Londha(2006) has also prepared peda by addition of boora i.e. siftedsugar (30% on khoa basis) after khoa was prepared from buffalomilk (5.9% milk fat). In plain peda making process, prolongedheating of milk leads to severe browning and loss of nutritionalquality. To overcome this problem, reverse osmosis technologywas adopted by Dewani and Jayaprakash (2004). For mechanizedproduction of peda, some plants have recently undertaken use ofmechanized equipment and Rheon extruder. However Patel et al(2006) reported that the pea manufactured using traditionalmethod was superior in chemical and sensory quality than thosemanufactured using mechanized methods.

Rabri

Rabri is a partially concentrated and sweetened milk productcontaining several layers of clotted cream. Based on marketsurvey, Gayan and Pal (1991b) has standardized method ofmanufacturing for rabri. A mechanized method of manufacturingof rabri employing SSHE for concentration of milk, and addition


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of shredded channa/ paneer in place of clotted cream (added intraditional method) has also been developed by Gayan and Pal(1991b). For large scale production of rabri, Pal et al ;2005successfully developed a technology using thin film scrapedsurface heat exchanger (TSSHE).

Basundi

Basundi is a heat desiccated, thickened milk dessert, prepared byrepetitive boiling of sugared milk. Patel , 1999 carried outsystematic studies to develop standardized procedure for makingbasundi on commercial scale, which was later recommended byPatel and Upadhaya ,2003. A mechanized prototype of scrappedsurface heat exchanger was designed and developed to suit thestandardized process of basundi making (Rajasekhar et al ; 2003).In order to evaluate the performance of three different shapes ofSSHE viz. Cylindrical type, conical type and Karahi type, overallheat transfer coefficient (U value) was taken in to consideration.The results showed that Karahi type SSHE could give higher Uvalue.

Gulabjamun

Gulabjamun are being manufactured commercially using khoaportioning and ball forming machines followed by deep fat fryingand sugar syrup soaking lines. (Banerjee, 1997). In newtechnology developed for industrial production of gulabjamunusing an assembly-line system is in use at Sugam Dairy Vadodara.Khoa with 30-40% moisture is mixed in a planetary mixer withabout 19-20% maida and 0.5% baking powder. In a portioningmachine dough is cut into 8 gm weights and conveyed to ballforming machine. The balls are carried to frying vat containingvegetable oil at temperature of 140oC. After proper cooking, theballs are shifted to sugar syrup tank containing syrup (62.5%solution). The gulab jamun balls are packaged in plastic containeralong with an appropriate amount of hot syrup. Then the plasticcups are heat sealed with lids and stored under refrigeratedconditions. Canned gulabjamuns are stoed at room temperature.

Heat and acid coagulated

Paneer and Channa are two prominent traditional heat and acidcoagulated products. Paneer the indigenous variety of cheese isprepared by acid coagulation of heated milk. The phenomenonof coagulation involves physical and chemical changes in caseinbrought about by heat and acid treatments. Channa, a base productfor a large variety of Indian delicacies is also heat acid coagulatedproduct. it differs from Paneer as no pressure is applied to drainwhey and its pH is slightly higher.

Paneer

In the traditional production process of Paneer, buffalo milk (6%fat, 9% SNF) is boiled in a vessel. To coagulate the milk whilestill hot, a suitable coagulant (lime/alum/citric acid) is added,

with slow stirring. Formation of clear whey is indicative ofcomplete coagulation. Stirring is stopped, as the coagulum tendsto coalesce. After the formation of large lumps is complete,contents of the vessel are poured over a muslin cloth to separatethe coagulum from whey. The coagulum so obtained is lightlypressed to facilitate formation of paneer blocks of suitable size,followed by their immersion in chilled water to impart themdistinctive texture.

Paneer manufacture has traditionally been an intensely manualoperation, requiring a large labour force and using equipmentthat could be used for a number of other processes. Paneermechanization describes the use of machinery to replace manualoperations in traditional small-scale manufacture and thedevelopment of equipment that was targeted at specific tasks. Afew studies which have been done on manufacturing of paneerare discussed under below:

To develop domestic gadget for paneer making, studies on wheydrainage and matting of curd were carried out using a test cell(Mudgal et al ; 1995a & b). Based on the findings a batch unitfor handling milk up to two liter was designed and developed atNDRI, Karnal (Bikram, 1995). For continuous paneer making, atwin-flanged apron conveyor cum filtering system was designedat NDRI to manufacture 80 kg paneer per hour for obtaining thedesired moisture content and texture attributes (Agarwala et al ;2001). Das and Das (2009) used an impact type device formanufacture of paneer. For the pressing, curd was kept in cagesmade from a special type of screen and the cages were subjectedto 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 offeradvantages like mechanization, uniform quality, improve shelflife, increased yield and nutritionally better product. In anotherapproach, a fully sterilization product has been developed whichgives a long shelf life paneer like product (Rao, 1996). Guptaand Pal (1995) observed that paneer made from milk concentratedby reverse osmosis to 1.5x (25% TS) and 2x (33% TS) resultedin higher yield by 2–3% on original milk amount basis comparedto control without affecting its sensory properties. Pal et al. (2002)conducted a study in which they concentrated cow milk to about1.5 and 2.0 folds using NF membrane system at 50 °C and foundthat the NF reduced the salt content of cow milk up to 74% in 1.5fold concentrations without affecting other major constituents.Kanawjia and Rizvi (2003) used microfiltration to develop paneerfrom skim milk concentrate utilizing three fat sources viz. butteroil, cooking butter and plastic cream which were incorporatedinto skim milk retentate using homogenization.

Cheese

Cheese is an analogous product to paneer and made from wholemilk, skim milk, cream or their mixture. Some cheeses are made


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from whey, whey cream or whey milk mixtures. According to theFood and Agricultural Organization of the United Nations, over20 million metric tons of cheeses were produced worldwide in2011. In total fewer than 25 varieties are popular in the world.The varieties may be grouped or classified into types accordingto criteria such as length of ageing, texture, methods of making,fat content, animal milk, country or region of origin, moisturecontent, presence of mold etc.—with these criteria either beingused singly or in combination but with no single method beinguniversally used (Ensrud, 1981). Depending upon above criteria,a list of classification of cheese is given in Table 1. (Anon 2011)

Many of the fundamental developments occurred from 1960 to1970 and were reviewed by several researchers. Investment inmechanized systems, including vats and mechanical curd-handlingequipment, has been extensive both in medium-sized and largeplants as discussed below:

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

Channa

In traditional production of Channa, a small portion of boiledmilk is transferred to a smaller coagulating vessel. The requiredamount of coagulant (usually the previous day sour Channa whey)is added to the hot milk and blended till the coagulation iscomplete. The vessel contents are then poured over a piece ofclean muslin cloth held over another vessel in which the wheygets collected. The coagulation process is repeated till all themilk is converted into Channa. The muslin cloth containing thecurd mass is hung to further drain out whey and to cool the Channasimultaneously.

To overcome the problems of small scale, attempts have beenmade to mechanize Channa production. The first prototype ofcontinuous Channa making machine of capacity 40Kg Channaper hour was developed at NDRI, involving tubular heatexchanger acid injector, hold and strainer (Aneja, 1977). IIT,Kharagpur has used similar principle and obtained a patent onthe mechanized production of Channa. The process involvesindirect 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 permitcomplete coagulation, separation of whey in a continuous flowemploying double wall basket centrifuge and chilling to 4°C, bydirectly spraying chilled water on the layer of Channa (Singh,1994).

Some innovations in manufacturing process of Channa such astray, spray and roller drying (Tewari and De, 1976), use ofconcentrated and dried whole milk after reconstituting it up to 15% TSS (Kawal, 1979; Singh, 1991), continuous dewatering of

Criteria Types of cheese ExampleAge Fresh Cottage cheese, Cream cheese etc.

whey Italian cheese, Greek cheese etc.stretched curd Mozzarella cheese

Moisture content or firmness Semi soft Domiati cheeseMedium 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,

goat milk and sheep milk Camembert cheese, Mozarella cheese, Channa 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 AppenzellerSmeared ripened Munster and Port SalutBlue Roquefort, Gorgonzola, and Stilton

Others Brined Feta, Halloumi, Sirene and Telemea etc.Smoked Raclette, Garroxta etc.

Table 1: Classification of cheese


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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 herbalcoagulants i.e. papaya and ginger extract (Singh et al ; 2005)have also been made to produce good quality Channa.

Channa based sweets

Because of limited shelf life of Channa lasting only few hoursand shortage of milk during lean season, traders have to facemany challenges. To overcome such problems, Singh (1991)standardized a method for preparation of good quality Rasogollausing dried milk. Traditionally, Channa balls are manually madeworking between palms. Kumar et al ;1997 designed a screwconveyor for kneading of Channa and a cutter provided at theexit split the Channa in to lumps of 10g each. The lumps aremade to fall on a spinning disc and stationery disc above, whichconverts lumps into round balls. Das (2000) developed a ball-forming device along with continuous cooker to mechanize theprocess of Rasogolla making. Another machine has beendeveloped which can do the dual job of Channa kneading andball making in continuous manner (Choudhary, 2002).Karunanithy et al ;2007 has also developed a Channa kneaderand ball former device and its performance was evaluated in termsof spherecity.

Technology for production of Rasogolla mix has beenstandardized by Pal et al (1993). Rasogolla prepared from buffalomilk is usually hard and lacks sponginess, as well as desired bodyand texture. Ramathilagam and Subramaniam (2005) investigatedthe suitability of buffalo milk for preparation of Rasogolla, bycarrying out certain modification in buffalo milk. Jayaprakash(2003) developed a technology for production of sugar freeRasogolla using different artificial sweeteners.

Kumar (1998) developed a single screw vented extruder forcontinuous production of Sandesh. It is claimed that about 80 %Channa produced in Kolkata is converted in to Sandesh (Anejaet al, 2002). Kumar and Das (2003) optimised the processingparameters for the mechanized production of Sandesh.

Tewari et al (1991) took an initiative for manufacturing of Channabased table spread. A low fat sweet dairy spread was developedby Babubhai (1999) keeping Channa and SMP as a major sourceof protein. Reddy et al (2003) standardized another proteinenriched table spread using Channa as a base along with butter.

Cultured/fermented products

Dahi, Yogurt, Mishti dahi, Chakka, Shrikhand and Lassi arefermented milk products. However they differ considerably interms of cultures used and their bouquet and flavour profiles.The Bureau of Indian Standards (BIS) specifications for fermenteddairy products are based on the type of culture used in theirpreparation. The culture is a soul of the product as it imparts

distinctive smell and flavour profile to the product. The detaileddescription and the recent technological advancements which havebeen taken place in manufacturing of cultured/fermented productsare discusses under below:

Dahi and yogurt

Dahi is an indigenous dairy product which is produced by lacticacid fermentation of milk. During fermentation of milk, a lacticacid bacterium (culture) hydrolyses the lactose in to lactic acidas a major product, which contributes to the more than 90% ofacidity to dahi.

Like dahi, yogurt is a semi solid fermented product made fromstandardized milk mix by the activity of symbiotic blend ofstreptococcus thermophilus and lactobacillus delbrueckii subsp.balgaricus cultures.

Traditionally dahi is prepared at small scale, either in theconfectionery shop or in the household. Milk is first boiled andthen cooled to room temperature. Inoculation is done with 0.5 to1.0 percent starter (previous day’s dahi or butter milk) followedby incubation for setting for about overnight.

Cup Thermo- fill and Sealing Machine is now-a-days most widelyused for the packaging of dahi. Thermoforming of cups from theplastic film, filling of product and sealing of lids take place incontinuous sequence of operation. The machine has a feed hopper,filling pumps, filling nozzles and stirrer. A major advantage ofthis machine is cutting down the cost of cups by 50%, since thecup is thermoformed and lid is punched right on the machineitself.

Chakka & Srikhand

Chakka is white pale yellow semi-solid product of good textureand uniform consistency obtained by draining off the wheyfrom dahi/yoghurt obtained by lactic fermentation of milk. Itis main ingredient for the manufacturing of shrikhand.Shrikhand an acid coagulated indigenous and sweetish sour,fermented milk product. It is prepared by blending sugar, flaourcolor and spices to chakka. It is popular delicacy in south-west parts of India, mainly Gujarat, Maharashtra and parts ofKarnataka. Although largely produced on small scale adoptingage old traditional methods, with growing demand, shrikhandis now commercially manufactured in organized dairy sector.

Aneja et al (1977) made successful attempts to develop anindustrial process for the manufacturing of shrikhand with aview of overcome limitations of traditional method ofpreparation.

The first modern plant for manufacturing of shrikhand wasestablished at Baroda District. Co-operative Milk ProducersUnion Ltd. (Sugam Unit) in Gujarat in 1980. Since then, it


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has been producing and marketing shrikhand under the brandname “SUGAM” & “AMUL” (Aneja et al ; 2002).

Aneja and Vyas (1983) developed a fully mechanized/continuous process for industrial production of shrikhand. Inthis process chakka was prepared by separating the whey fromskim milk dahi employing 28" diameter basked centrifuge at1100 rpm. The resultant chakka, sugar & plastic cream arethen mixed in a planetary mixer.

Increasing demand for these products present a greatopportunity for the organized dairies in the country tomodernize and scale-up the production. A GCMMF-TCSSurvey report has given projected demand of Ghee, Paneer,Shrikhand, Rasogolla, and Gulabjamun to be 200, 16, 5.7, 6and 5.9 thousand metric tones by year 2009 (Misra, 2000).Therefore, the expanding business prospects provided by theseproducts and their accompanying value-addition call for athorough study of this sector. There is a need to look intovarious issues and accordingly re-evaluate and re-engineerourselves to modernize traditional dairy products sector.

Lassi

Lassi scientifically is defined as a fermented milk beverageobtained after the growth of selected culture, usually lacticacid streptococci, in heat treated or partially whole milkfollowed by sweetening with sugar. It is prepared by breakingthe curd into fine particles by agitation, addition of sugar waterand optionally flavour. By-product obtained in the preparationof desi butter from dahi by indigenous method is also knownas lassi. There has been no advancement in mechanizationfor Lassi manufacturing but packaging sector used Form-Filland Seal Machine(FFS) for packaging of lassi in 60-80 microsLLDPE co-extruded pillow type pouches. Its operation issimilar to that of ghee pouch FFs machine. Other than thesespackaging machinery research has been done in technologyadvancement 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 withbuttermilk to get a slurry with soy-solids-buttermilk solids ratio2:1. The slurry (12% TS) was homogenized (175 and 35 kg/cm2 at 65oC), pasteurized (85oC) and inoculated with L.Bulgaricus+ S. thermophilus @2%. After incubation at 37oCfor 10-12 h, dahi was sweetened with sugar syrup andthoroughly mixed. The resultant lassi had 10 days storage lifeat 5oC in polyethylene pouches.

Kumar et al (1987) developed a lassi type cultured beveragesfrom cheese whey. Skim milk and cheese whey in ratio of 5:95were 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 shelflife of lassi apart fron cold storage. Addition of nisin @200-300 IU/ml and 400-500/ml extended the acceptability to 24and 32 hours respectively compared to 8hr for control at 30oC.

Kumar (2004) developed lassi like beverage from rennentwhey. 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 toUHT- treatment. The milk result suggests that milk cna bereplaced by 70% panner or cheese whey in preparation of lassilike beverage.

Fat rich products

Butter and Ghee are the prominent products under this section.Humans are familiar to this product since centuries andaccording Indian texts, it was first mentioned in 8th centuryBC. Since that time many new technologies had been adoptedfor manufacturing at household and then at commercial levelproduct.

Nearly 90% of Ghee produced in country is made by traditionalmethod. Increased awareness about energy management in pastmotivated the research works of develop energy efficient andcontinuous method for ghee manufacturing (Punjrath 1974),which include either an oil separator (Bhatia 1978) to separateserum and fat phase or use of scrapped surface heat exchangers(Abhichandan et al ; 1995). Both the process save energy andyield a comparable product.

NDRI have tried to modify, scale up the traditional method ofghee making into continuous method. The mechanized processis used for producing butter oil involving centrifuge separationof moisture followed by final dehydration under vacuum.However, the product was lacked typical ghee flavour.

Small Group Activity (SAG) team was constituted under TQMprogramme at Panchmahal Dairy, Godhra, which worked onimprovement in production technology of ghee making. Theprocedure finalized with inclusion of serum separation and aspiro heater in the process. The cream used was firstpasteurized using HTST at 90-92°C and pumped to ContinuousButter Making Machine (CBMM) where in butter is obtained.White butter is melted by pumping through Spiro-heater. Theghee made by this process is fetching premium price in market.

The use of FFS machine in ghee packaging is becoming verypopular. 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 filmused is coextruded LLDPE/LDPE or polystyrene/nylon.

Milk based deserts/pudding


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Consumer’s convenience along with safety is key to valueaddition in dairy and food processing industry. In this contextKheer and dalia are two important cereal based food product,which are popular throughout the country but have noorganized manufacturing and marketing system (Aneja, 1977).

Kheer is popular in northwest central and eastern parts of thecountry and is popular as Payasam in the southern states.Similarly, dalia as a milk-wheat porridge is quite common ismany parts of country both as breakfast food as well as healthfood.

Despite of such huge popularity the cereal based sweetscontinue to be made much in traditional manner only fewattempts have been made to mechanize the processingtechnology which include use of steam-jacketed kettle formanufacturing of kheer, using steam process. Rice puddinghas also been manufacturing employing a scraped surface heatexchange (SSHE).

A process has recently been developed at NDRI, Karnal forin-package cooking and sterilization of kheer in retort poucheswith the objective to enhance its shelf life at ambienttemperature. The kheer obtained by this process had shelf lifeof more than four months at 37°C.

In order to promote dalia desert as a marketable product aprocess has been developed for manufacturing of instant daliamix, use of fluidized bed drier and spray drier has been madein manufacturing instant dalia mix. The product so developedwas packed in PE-paper board cartons. Reconstitution inboiling water yields a product, which is highly acceptable.

Mechanization in cereal milk based deserts is still required asdevelopment of suitable process for commercial manufacturingof cereal-milk based convenience foods will hopefully providea necessary fillip to the contribution of traditional dairyproducts its national dairy economy.

Developments in packaging

The traditional dairy products have been conventionally packagedin dhak leaves, paper cartons, polyethylene bags or cardboardboxes. These traditional packages do not provide sufficientprotection to the product from atmospheric contamination andalso do not have the functional properties in order to preserve theinitial quality of the product for a longer time. As a result, theproducts soon loose their typical body and texture, pick up foreignodors, become rancid/oxidized and give undesirable appearance.These packages are also not suitable for far-off transportationand outstation retail sales (Goyal, 1998).

Recently, with the rapid developments in packaging technology,substantial progress has been made in packaging of traditionaldairy products. Packaging of Khoa in laminates of paper/Al.Foil/

LDPE (55-60 gsm, 0.02 mm and 159 gauge), and Polycel (300, 150gauge poly, colored) have been found to be quite satisfactoryfor Khoa. In these packages, Khoa can remain in good conditionfor 10 days at ambient temperatures and 60 days underrefrigeration conditions. However, by using 4-ply laminatedpouches made of PP/LDPE/ Foil/LDPE, the shelf life of Khoacan be increased to 14 days at 30ºC and 75 days in cold storage(Kumar et al. 1975). For packaging of Chhana, polycel (300 and150 gauge, colored) is good, low-cost packaging material.

Ghee is generally packaged in lacquered or unlacqured tin cansof various capacities ranging from 250g to 5 kg for retail saleand 15 liters for bulk sale. Some dairies pack ghee in polyethylenebags. Other recommended packages for packaging of ghee arepolyester coated cellophane, polyester, nylon-6, food grade PVCor their laminates.

Recently, systems have been developed for assembly linepackaging for Shrikhand, Dahi, Misti Doi, Paneer, etc. and arebeing used in organized sector. Polystyrene or polypropylene cupsused for packaging of Paneer extend shelf life of 180 days at -18ºC and 30 days at 5ºC. Rasogolla are being packed in lacqueredtins with a shelf life of 6 months at room temperature (Chandanet al ; 2002). Polypropylene trays covered with transparent,coloured MXXT are recommended packages of Burfi, Peda andKalakand (Goyal ,1998). Low weight, leak-proof lacqueredkulhers for packaging dahi, misti doi, etc. have been developedat NDRI, which give better shelf life than plastic cups.

Conclusions

The Indian milk sweets enjoy mass appeal, give high profitmargins and have high export potential. There is an urgent needto modernize this sector to produce high quality products withlong shelf life. We need to generate basic data on these productswhich will help for designing of new equipments or for intelligentselection of existing food processing and packaging lines. Greatscope also exists for improving the shelf life of milk sweets byemploying newer preservation techniques. While lots ofinnovations have taken place recently, these innovations have notpercolated to the actual users. Industry-R & D organization linksneed to be strengthened for designing machinery for commercialmanufacture of traditional dairy products. Innovation in marketingis equally important. It is possible to popularize indigenous dairydelicacies through the fast food chains or franchising of somepopular brands of Indian dairy delicacies may be promoted.Collecting market intelligence to inspire confidence amongprospective entrepreneurs to take commercial production oftraditional dairy products in India and abroad is also essential.Collaborative efforts of industry, unorganized sector, equipmentmanufacture and R & D institutions are required for all rounddevelopment of traditional dairy product sector.


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A review on mechanization of traditional dairy products

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