1 Dairy Technology 1 EXPERIENTIAL LEARNING. ( Dairy Technology Programme). 1. Name of the Experiential Learning Unit Processing of Milk & Milk Products 2. Location with Address Department of Dairy Technology 3. Objectives To impart hands-on-training/Experiential learning on Processing of Milk & Milk Products in a commercial environment to sharpen their technical as well as managerial skills thereby enhancing the professional confidence and to provide an opportunity to develop a set of skills such as leadership, teamwork, interpersonal communication, analytical problem solving, entrepreneurial/business skills which are not gained in a class room environment. 4. Activity components Experiential Learning Protocol in Pilot Dairy Plant Duration: One year a) Experiential Learning in Pilot Dairy Plant: 8 months b) Industry Attachment: 4 months Credits: Total 40 credits a) Experiential Learning in Pilot Dairy Plant: 25 Credits b) Industry Attachment: 4 months: 15 Credits Training Modules: a) Experiential Learning in Pilot Dairy Plant: Duration: 8 months Module Duration 1 Development of a Bankable Business Proposal: Students Simultaneously in designated groups shall develop a bankable proposal of with following Techno-economic feasibility for manufacture of a product modules mix assigned by the training in-charge as per the guidelines given in Annexure-1.
2 Understanding the requirement of various permits and licenses for establishment of commercial milk processing unit and procedures for obtaining the same. 2 Milk Procurement: Attachment with milk collection/ 3 weeks chilling centre to understand intricacies involved in milk procurement, interaction with milk producers, issues &. constraints in milk procurement and transportation of raw milk. 3 Hands-on- Training and Experiential Learning: The in- 4-8 weeks per charge Pilot Dairy Plant shall prepare not less than 4 product mix. different product mix to be manufactured daily by the 2 students on commercial basis. All the students shall be divided in groups, each group manufacturing a given product mix daily in quantity sustainable at commercial level.
3 The student group shall be responsible for a given product mix from procurement of raw material to processing including packaging and storage, conduct manufacturing, organize resources and utilities, sell the product, maintain accounts and documents, wind up production and submit the report of performance. Students shall be rotated after prescribed duration so that each group has acquired hands- on training on all the product mixes. 4 Report writing: As per Guidelines given in Annexure 2 Simultaneously b) Industry Attachment: Duration: 4 months 1. During this period the students shall be placed in reputed Dairy plant to get exposure of working in an industrial set up. Each college shall nominate a placement officer who shall be responsible for placement of students.
4 The Dairy plant chosen for industry attachment should preferably be a multi-product factory with turnover of more than 2 lakh litres of milk per day. 2. One teacher shall be appointed who shall visit the dairies from time to time to monitor the training and evaluate the students' performance jointly with industry representative responsible for training. Infrastructure required i) Civil work S. No. Description Total area, Rate, Total cost, sq. ft. ft. Rs. 1 Experimental Dairy 3000 2000 60,00,000. 2 Milk Parlor 500 2000. 10,00,000. ii) Equipment/Machinery required S. No. Description Quantity Cost (Rs. in lakhs). MILK RECEPTION SECTION. 1 Can Tipping Bar (MS) 1 No. 2 Can Scrubber 1 No. 3 Roller Conveyor 1 No. 4 Weighing Scale 500 kg.
5 1 No. 5 Weigh Bowl 250 kg 1 No. 6 Dump Tank 1000 ltrs 1 No. 7 Conical filter 1 No. 8 Milk Pump 1 HP 1 No. 3 MILK PROCESSING SECTION. 1 Pasteurization Plant 2000 lit/h 1 Unit 2 Triprocess cream Separator 2000 lit/h 1 No. 3 Milk Pump 2000 lit/h 2 Nos. BUTTER & GHEE SECTION. 1 Butter churn 1 No. 2 Ghee Kettle 500 lit 1 No. 3 Ghee Tin Seaming Machine 1 No. 4 Cream Vat 500 lit 1 No. DRY MILK SECTION. 1 Spray drier (10 lit water evaporation/h) with 1 No. condensing unit ICECREAM SECTION. 1 Ice cream freezer 1 No. 2 Homogenizer 1 No. 3 Mix aging tank 1 No. 4 Hardening Room 1 No. STORAGE SECTION. 1 Milk Storage Tank 2000 lit (Double walled 3 Nos insulated) 2 Milk Pump 2 HP 3 Nos PACKING SECTION. 1 Form Fill Seal Pouch Filling Machine (2000 2 No.)
6 Packs/h). REFRIGERATION SECTION. 1 Cold Storage Room 200 CBM 1 Room 2 Refigeration Unit with Hermetic compressor 1 Nos. (2 Nos). QUALITY CONTROL LAB. 1 Quality control equipment - UTILITY SECTION. 1 Steam Boiler 100 kg/h 1 unit 2 Water Softening Plant 1 unit 3 Steam Pipe Line ( ) 1 Lot 4 Air Compressor (For Pouch Packing) 1 No. 5 set 125 KVA 1 No. 6 Pipes & Fittings 1 Lot 7 Water pipe line 1 Lot 8 Chilled water pipe line 1 Lot 9 Electrical control panel & wiring 1 Lot 10 Effluent treatment plant 1 Lot 11 Maintenance Unit 1 Lot 4 INSTALLATION & COMMISSIONING. 1 Total cost of Plant & Machinery including Sale Tax, Excise Duty, Packing charges and Transportation 2 Miscellaneous Total Cost of equipment Total Cost (Building + equipment) Recurring contingency required The recurring contingency will be required for the purchase of milk and other raw materials, ingredients, packaging materials, spares, etc.
7 The total recurring contingency required would be Rs. 10 lakhs. Total budget required The total budget required for establishment of the experiential learning unit will be Rs. lakhs (Cost for building & equipment, + Recurring contingency, 10. lakhs). Support for Guest Faculty required The Guest Faculty is required to deliver special lectures on preparation of bankable project proposal, maintenance of Dairy plant, waste disposal and environmental issues, energy audit and energy saving, quality audit and quality assurance, export orientation and certification, marketing issues, financial management, legal issues, successful entrepreneurship case studies, etc. Economics Gross turnover/profit statement (For a batch of 20. students).
8 Financial viability of a Mini Dairy Processing Plant for Experiential Learning for total milk handling of 2000L/Day has been worked out as under: Product Mix Quantity Quantity of Sale Total Sales of Milk Products Price, Revenue, Manufactured Rs. Rs. 1. Market Milk 600 lit 550 lit 27/- 14, (Toned milk). 2. Ghee 100 lit 60 kg 350/- 21, 3. Dahi/ Lassi 500 lit 500 kg 50/- 25, 4. Ice Cream 400 lit 400 kg 60/- 24, 5. Burfi 400 kg 100 kg 200/- 20, Total 1,04, Rs. 5 Total Expenditure including Raw Materials Cost Items & Expenditure Rate Total Cost, Rs. 1. Milk purchase 30/-/lit 60, 2. Ice Cream Raw Materials - 3. Processing Cost @ Rs. 4/lit 4/- 8, 4. Packaging Cost 5, 5. Losses @ 3% 1, 6. Staff Salaries (Technical 5, assistants: 02 for refrigeration &.)
9 Electrical, Processing @ Rs 2500/per person/month). 7. Depreciation @10% 10/- 8, 8. Marketing @ 5% of sale price 5, Total Rs. 97, Net Savings per Month S. No. Details of Items Amount in Rs. 1 Total Sale Price per day 1,04, 2 Total Expenditure per day 97, 3 Net savings per day 7, 4 Net profit per month 2,13, Profit/Loss and guidelines for sharing profit The profit will be shared by the students, department and the faculty involved in the programme. The profit share will be as follows: 1. Students - 75%. 2. Department - 15%. 3. Unit Manager -10%. Payment of honorarium to Faculty @ , per month and Honorarium to Staff @ Rs. per month may also be considered from the profit. If the EL unit is found to register loss, remedial measures should be taken by the monitoring team.
10 If it is not rectified, it should be closed immediately. Thorough planning should follow. Experiential Learning Protocol for Dairy Science Colleges having Commercial Dairy plant Duration: One year a) Hands-on-training in Model/Vidya Dairy : 8 months b) Industry Attachment: 4 months 6 Credits: Total 40 credits a) Hands-on-training in Model/Vidya Dairy : 30 Credits b) Industry Attachment: 4 months: 10 Credits Training Modules: a) Hands-on-training in Model/Vidya Dairy : Duration: 8 months Module Duration 1 Development of a Bankable Business Proposal: Simultaneously Students in designated groups shall develop a bankable with following proposal of Techno-economic feasibility for manufacture modules of a product mix assigned by the training in-charge as per the guidelines given in Annexure-1.