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The milk industry is experiencing rapid advancements and unprecedented growth, necessitating a comprehensive resource for professionals, students, and researchers engaged in this dynamic field. This book, "Milk Processing and Dairy Technology: Principles, Products, Practices and Standards" aims to serve as an essential reference, offering an in-depth exploration of milk production and processing technologies. In this book, we cover a wide range of topics integral to the milk industry. Starting with major milk production practices, we delve into processing techniques, transportation logistics, and the nutritional composition of milk. The book also addresses critical aspects such as milk storage, processing, microbial spoilage, milk defects, and the diverse array of milk byproducts. We emphasize the significance of packaging, distribution, and transportation, as well as the essential practices of cleaning and sanitation in milk plants. While there are numerous publications on the subject, there has been a longstanding need for a single, comprehensive source of updated information, particularly one that benefits undergraduate students. This book aims to fulfill that need by presenting concise, yet thorough, coverage of all relevant topics. Our goal is to provide readers with the most current and accurate information available, supported by appropriate tables and figures to enhance understanding. This endeavor has been a collaborative effort, involving contributions from numerous experts who have generously shared their knowledge and insights. While it is impossible to individually acknowledge everyone who has contributed, their collective efforts have been invaluable in the creation of this book. To all who have played a part in this project, I extend my deepest gratitude. I invite readers to share their comments and suggestions, as your feedback is crucial for the continuous improvement of this work. I hope this version of the preface effectively captures the essence and purpose of your book while providing a clear and engaging introduction to its contents.

1.1 Introduction The rural economy has greatly benefited from dairy farming. In rural India, milk has become a substantial source of revenue. Dairy products, including milk, are vital components of modern diets. India holds the title of being the greatest milk producer and consumer globally. Together with native cattle, crossbred cattle, and water buffalo, it also has the biggest dairy herd. Since 2000, there has been a steady and substantial annual growth rate of 4.2 percent in both milk production and consumption. Additionally, second, respectively, in terms of population (GoI, 2014). It accounts for around 25% of the global bovine population. India has emerged as the leading global producer of milk, with a remarkable production of over 155.5 million tonnes during the 2015- 16 period. This translates to a per capita availability of 337 grammes per day, according to the Government of India (GoI, 2017). Dairy farming serves as a primary means of subsistence for more than 100 million individuals. A significant percentage of small-scale livestock keepers lack access to land, and the prevalence of rural landless households is expected to rise due to the continued subdivision of land holdings. Livestock are increasingly vital for the income of smallholder and landless farmers. These initiatives have positively impacted the farmers’ food production, nutrition security, and household income. Additionally, they have played a crucial role in creating employment opportunities in rural areas.

2.1 Introduction Typically, milk is obtained from domesticated animals (water buffalo, sheep, or goats) under farm-level circumstances. In smaller amounts, it can be utilized directly after boiling; but, in larger quantities, processing and storage are crucial. Farms provide their milk to milk vendors, who collect it in cans and deliver it to chilling centers or dairy processing plants. After milking, the milk is quickly chilled to 4°C, or it should be pasteurized and packaged within two hours. Before being marketed, milk must be pasteurized, with the exception of products that initially require raw milk or those that require direct application of heat, such as desiccation or another heating process. The market for novel goods and procedures is steadily growing. The main causes include rising disposable incomes, shifting consumer attitudes and concerns about safety, hygiene, and nutrition, and the entry of foreign companies. 2.2 Dairy plant requirements The plant should be situated in an area free from waterlogging, well- protected, easily accessible by car, and equipped with a plentiful supply of drinkable water, a facility for disposing of waste, and energy. 2.2.1 Infrastructure requirements For the receiving of milk, chilling, storing, separating, pasteurizing, homogenizing, packaging, and product manufacturing, civil works with appropriate space and machinery are needed. provisions for utility units such steam generation and refrigeration control, storage, and quality control. When choosing metals for equipment in dairy plants, look for materials that are nontoxic, tainting, corrosion-resistant, easy to clean, affordable, and long-lasting. Generally, alloys made of aluminum or 18:8 stainless steel are recommended.

3.1 Introduction The mammary glands of mammals produce milk, an opaque milky liquid. It is the primary source of nutrition for young mammals before they are capable of digesting other forms of food. The immunoglobulins are transported to the young ones by the early secretion of udder immediately following parturition, which is referred to as colostrum. It has the potential to mitigate the risk of numerous maladies in newborns. The precise composition of fresh milk varies depending on the species, but it contains substantial quantities of calcium, protein, and fat. The mammary glands of mammals produce the opaque white liquid known as milk. Up until they are capable of digesting other types of food, it is the primary source of nutrition for juvenile mammals. Milk serum is defined as milk plasma minus casein micelles, a composition that is similar to that of whey. The major constituents of milk are Water is the medium through which the other milk constituents are dissolved or suspended. The majority of the fat in milk is present in the form of small globules, with an average size of 2 to 5 microns (with a range of 0.1 to 22 microns). This is known as milk fat (lipid). Fat is present in an oil-in-water emulsion. Milk fat is composed of numerous fatty acid glyceride esters; when it undergoes hydrolysis, it produces a mixture of glycerol and fatty acids. Proteins from milk: Proteins present in milk: Protein is one of the most intricate organic substances. Proteins are composed of numerous amino acids; some amino acids are essential, while others are not. In order for the body to synthesise proteins, the diet must include the essential amino acids. The preponderance of the proteins in milk are composed of whey proteins, beta-lactoglobulin, and alpha-lactalbumin. Milk is the primary source of casein, a calcium caseinate phosphate compound.

4.1 Introduction At the moment of secretion in the udder, milk is sterile; however, it is contaminated by bacteria before it is extracted from the udder. With the exception of mastitis, the bacteria are generally innocuous and restricted at this juncture. Microorganisms may contaminate the milk further during milking, handling, storage, and other pre-processing activities. The bacteria have the potential to either enhance the quality of milk or cause it to deteriorate. Some of the beneficial bacteria, particularly the lactic acid bacteria, are referred to as probiotics. These probiotics are gaining a more prominent position in nutraceutical dairy and other food products, which provide consumers with health benefits such as the control of diarrhoea, antihypertensive, hypocholesterolemia, immunostimulatory, and anticarcinogenic properties. 4.2 Lactic acid bacteria This particular group of bacteria is capable of homofermentation, which is the process of fermenting lactose to lactic acid, and heterofermentation, which is the process of generating a high number of end products. They are commonly present in milk and are also used as starter cultures in the production of cultured dairy products, such as yoghurt.

5.1 Introduction The process of milk processing entails the transformation of liquid milk into dairy products, including pasteurised liquid milk, yoghurt, butter, cheese, and ghee. The following are the rationales for processing: There are numerous benefits to processing milk, including the ability to access distant markets, the extension of the product’s storage life, and the attraction of higher prices because of its enhanced transportability. Furthermore, processed products are less cumbersome and lighter, which facilitates transportation. The refining of milk improves its quality and hygienic safety, enabling the production of a variety of milk products, including cheese and liquid milk, to satisfy the diverse needs of consumers. Additionally, the processing industry contributes to economic development by creating employment. Small-scale processors are capable of producing a wide range of dairy products. Before determining which dairy products the group will produce, it is recommended that a comprehensive market/feasibility study be conducted. Milk products can be processed in the manner depicted in the image.

6.1 Introduction The majority of milk demand is urban, while production is restricted to rural areas in nearly all developed dairying countries. Consequently, milk must be collected and transported from production sites in the milk-shed areas to processing and distribution points in cities. The common systems for collection (assembling) of milk are as follows. 1. Through a cooperative organisation. Established by collective or individual dairy societies. Producers are most advantageous when there are no intermediaries involved in profit labelling. 2. by contractors. Producers receive a diminished return. 3. By independent producers. Convenient for individuals who reside in close proximity to dairy processing facilities. Note: The milk shed is the geographic region from which a city dairy obtains its fluid milk supply. India is currently contemplating the allocation of specific milk silos to individual dairies in order to facilitate their development.

7.1 Introduction Certain bacteria are present in milk that is extracted from the udder; they increase in quantity as it is processed further. The optimal temperature range for the proliferation of typical milk bacteria is 20 to 40 degrees Celsius. The formation of unpleasant flavours, increased acidity, and other factors always results in a decline in market quality following the proliferation of bacteria. Prompt chilling to a low temperature is one method of preserving milk. Milk jug Refrigerator: In order to preserve the purity of the milk received at the Dairy/Chilling Centre, it is chilled to 4°C using a milk chiller. Stainless-steel plates comprise the chiller. The process of chilling involves the circulation of chilled water from one side of the plates and milk from the other. 7.2 Methods 1. In can or can immersion method: The milk is not only cooled, but it also remains cold, necessitating a significantly smaller mechanical refrigeration unit. This is achieved by transporting pails. Benefits of a surface cooler • Efficiently and swiftly transfer heat. • Relatively affordable. • Additionally, the milk is aerated, which enhances its flavour.

8.1 Introduction The chemical composition of milk intended for market or milk product manufacturing must be standardised in numerous dairy processes. Standardising milk may necessitate the regulation of a single component (typically fat) while permitting the other components to shift or regulate two or more components concurrently. Definition: The term “standardisation” of milk denotes the process of adjusting the fat and solids-not-fat percentages of milk to the desired value in order to comply with the legal or other requirements. Objectives of standardization are 1. To ensure that specific milk and dairy products meet legal requirements. 2. To offer a consistent product to the consumer. 3. To guarantee economic efficiency in production. The volume of milk available for sale is increased by the addition of skim milk, and the separation of cream enables the production of other value-added dairy products, such as butter, table cream, or other high-fat products.

9.1 Introduction The term “pasteurisation” is derived from the Frenchman Louis Pasteur, who demonstrated that the preservation of wine was enhanced by heating it to a temperature of 122 to 140 °F, which eradicated spoilage organisms. This occurred between 1860 and 1864. The utilisation of this procedure resulted in the development of a new term, “pasteurisation,” which rapidly acquired popularity in the field of technology. Although Louis Pasteur was a pioneer in the discovery of the use of thermal treatment to preserve wine, the process of pasteurising milk was initially attributed to Dr. Soxhlet of Germany in 1886. 9.2 Heat treatment of milk In the context of market milk, pasteurisation is currently defined as the process of heating each component of milk to a minimum of 63°C for 30 minutes, 72°C for 15 seconds, or any other temperature and duration that achieves the same level of effectiveness. Equipment that has been certified and functions properly is required for this process. The milk is promptly chilled to a temperature of 5°C or lower after the pasteurisation procedure.

10.1 Introduction Developed in the 1950s, ultra-high temperature pasteurization typically involves no hold using a temperature range of 135°C to 150°C. Immediate aseptic packaging determines how well UHT heat treatment of milk works. 10.2 Uperization Developed in Switzerland, this is generally known as “ultra – pasteurization”. Milk is heated in this method under direct steam up to 150 °c for a fraction of a second. One is always learning from this. Fore warming milk to 50 °C is the first stage in the uperization process, meant to eliminate most of the dissolved oxygen and volatile off-flavours by vacuum treatment. In the second step, the milk is first preheated to roughly 80–90 °C and then heated on the uperization chamber under high-pressure steam to roughly 150 °C for ½ to ¾ a second. The product moves into an expansion chamber at almost atmospheric pressure after this heating, therefore inducing some evaporation of moisture. The good is then transferred to a chiller and subsequently into a storage chamber. The advantages of uperization are • Long keeping quality. • Removal of feed and other volatile off-flavours: • Appreciable homogenization effect. • Reduction in acidity. • Efficient destruction of microorganisms. • Effect of uperization on nutritive value and flavour are not greater than that of pasteurization.

11.1 Introduction “Homogenization” is the method of mechanical treatment producing a stable emulsion of milk fat and milk serum. Homogenizer is the name given to the equipment employed for this aim. The fat globules in milk range in size from 1 to 20 microns; the average is 4 to 6 microns. The homogenizer reduces the size of the fat globules in milk or cream passing through it. The most of them are less than two microns. After homogenization, no cream line develops on milk; churning homogenized cream cannot generate butter grains. Moreover, milk like cream’s viscosity is changing, which increases the resistance the smaller fat globules face. The increase in viscosity is ascribed to the fact that more milk protein will be deposited on the surfaces of more fat lobules. Homogenizing milk changes its clotting characteristics, so the curd made with rennet or pepsin is supposed to be softer. Because lipolytic enzymes adsorbed on the extra surfaces provided by the more numerous tiny fat globules hydroly fat, homogenized milk or cream may become rancid more quickly than untreated goods. The milk or cream must be pasteurized either right before or right after homogenization to prevent these changes. Usually, the milk is homogenized after main heating and then pasteurized. Driven via a small valve against hard surfaces, heated milk is under pressure of 2500 psi and in a second stage under 500 psi. With a 1/10000 inch diameter, the aperture the liquid is driven through is quite small. Mechanical force milk through a narrow passage at high speed produces homogenized milk. This produces a stabile fat emulsion and breaks down the fat globules in milk into considerably smaller ones. Homogenization reduces the inclination of the fat globules to cluster and merge into cream. Milk is an emulsion whereby fat globules are distributed across a constant skim milk phase. Raw milk left to sit will finally cause the fat to climb to the top and form a cream layer. By means of a small opening under high pressure, homogenization mechanically breaks down the fat globules. While increasing their number and surface area, this lowers the average size of the fat globules. Practically speaking, the net effect is a substantially decreased inclination for creaming of fat globules. Three elements contribute to this increased stability of homogenized milk: a decrease in the mean diameter of the fat globules (a factor in Stokes Law), a decrease in the size distribution of the fat globules (causing the speed of rise to be similar for most globules such that they do not tend to cluster during creaming), and an increase in density of the globules (bring them closer to the continuous phase) owing to the adsorption of a protein membrane. < Heat pasteurization also breaks down the cryo-globulin complex, which often clusters fat globules causing them to increase. The homogenizer consists of a high-pressure pump with an adjustable opening based on a minute orifice. High pressure force of fluids through the orifice causes a notable change in the physical characteristics of the treated product and generates a very intimate combination of the fluid components. Annexure- II has a Homogenizer schematic.

12.1 Bactofugation Using a specially constructed hermetic centrifuge, the Bactofugation® method separates bacteria—including especially the spores produced by particular bacterial strains—from milk. The RPM rises to 60000. Since their density is larger than that of milk, this technique has shown to be a quick approach of lowering the spore count in milk. Usually separating the milk into a portion more or less free from germs, bactofugation produces a concentrate (bactofugate), containing generally both spores and bacteria in general and amounts to up to 3% of the feed to the Bactofuge. 12.2 Dehydration One can preserve the milk by dehydrating to different degrees. The “shelflife” of the dehydrated milk is longer than that of milk kept refrigerated and pasteurised. Concentrated or dry milk (milk powder) is milk from which some or all of the water has been removed. More than eighty-percent of milk is water. Eliminating water can help to preserve milks the best way. One can accomplish it freeze drying or by drum or spray drying. 12.2.1 Condensed Milk Eliminating some of the water from whole or partially/fully skimmed milk, either with or without sugar, results in condensed milk. Generally speaking, “condensed milk” is “full cream sweetened condensed milk,” whereas “evaporated milk” is used for “full cream unsweetened condensed milk.” Variations in skimmed milk are labeled “sweetened condensed skim milk” and “unsweetened condensed skim milk.” For full cream products, milk solids have a concentration ratio of about 1:2.5; for sweetened condensed skim milk, that ratio is 1:3. Annexure-I has an exhaustive composition chart for condensed milk.

13.1 Introduction Drying is the process of evaporation separating a liquid from a substance or mixture of components. Either solid or solid–liquid phase describes the product to be dried. The separation follows a solid and a gas phase pattern. “Milk Product” is a product derived from milk processing that might include food additives and other substances functionally required for the milk product as approved in the laws (FSSAI Milk standards). Made to increase the storage life of the product, lower bulk so as to cut packaging and shipping costs, etc., dried milk products are created. 13.2 Dried milk “Dried milk or milk powder is the product generated by the removal of water by heat or the equivalent means, to produce a solid containing five percent or less moisture. Dried whole milk or whole milk powder (WMP) from whole milk; and from skim milk is known as Dried Skim Milk or Skim Milk Powder (SMP), or Non-fat Dry Milk (NFDM); respectively 13.3 Whole Milk Powder Dehydrating milk from cows, buffaloes, or a combination of both or from milk that has been standardized results in whole milk powder. Up to 0.3% of the weight of the product might be calcium chloride, citric acid, sodium citrate, and sodium salts of orthophosphoric and polyphosphoric acids; also included butylated hydroxy anisole up to 0.01% by weight. The label does not have to list these additions. Milk powder must to have a fat level at least 26.0 percent and a moisture level no more than 5.0 percent. Measured as lactic acid, its overall acidity should not be more than 1.2 percent. The Coliform count should not be more than 90 per gram; the normal plate count should be just 50,000 per gram. For roller-dried goods and spray-dried goods, the solubility index shouldn’t be higher than 15.0 or 2.0.

14.1 Introduction India is now the top producer of milk globally, accounting for 13.1% of the world’s total milk output. Fresh milk, if left at room temperature, will spoil within a few hours. To extend its shelf life, some of the fresh milk can be converted into fermented products. This fermentation process not only prolongs the product’s shelf life but also enhances its flavor and makes it easier to digest. Historical evidence suggests that people have been making fermented milk products since as far back as 10,000 B.C. Various strains of Lactobacilli have been cultivated in labs to create a diverse array of cultured milk products with unique flavors. Since as early as 10,000 B.C., milk has been utilized to produce fermented dairy items in different parts of the world. These fermented products offer benefits such as improved digestibility, distinctive tastes, added probiotics, vitamins, minerals, and extended shelf life. There is an enormous diversity of fermented dairy products globally, with each product’s characteristics influenced by the local strains used in the fermentation process. 14.2 Lassi In India and Pakistan, lassi is a somewhat common beverage. It is produced by combining Indian spices with water or milk and curd or yogurt. Sweet lassi is made with sugar or fruits rather than spices; traditional lassi, sometimes called salted lassi, or just lassi, is a savory beverage occasionally seasoned with ground roasted cumin.

15.1 Introduction Milk is a multifaceted physiological fluid that aids infants in their transition to life outside the womb by supporting digestion and development, as well as providing essential nutrients and bioactive components. It promotes the development of beneficial microflora and enhances the growth of lymphoid tissue. Recent research indicates that the quantity and importance of bioactive compounds in milk may be greater than previously believed. Through research, the distribution and presence of essential components in various animal milks have been analyzed. The consumption of dairy products has been linked to health benefits that mitigate the adverse effects of obesity and overweight. These benefits include a decreased likelihood of being underweight, reduced blood pressure, and a reduced risk of stroke, colon cancer, and osteoporosis. Dairy products provide a valuable combination of nutrients, such as proteins, fatty acids, vitamins, and minerals, that are essential for the maintenance of blood health, the support of the nervous and immune systems, the improvement of vision, the support of muscle and nerve function, the maintenance of skin health, the maintenance of energy levels, and the overall growth and repair of the body. Furthermore, dairy products can function as carriers for bioactive compounds and may provide a variety of health benefits, such as improved immune function, reduced risk of cardiovascular disease, reduced bone mass loss, and protection against free radical damage, when consumed in an appropriate quantity. Incorporating fruits and vegetables in a variety of forms—including fresh, desiccated, powdered, juiced, pureed, pulped, or extracted—into dairy products such as yogurt, ice cream, and cheese also presents an opportunity to improve their health benefits.

16.1 Introduction The fluid product “Cream” is defined by FSSAI standards as an emulsion of fat-in-skimmed milk that is comparatively rich in fat. It is derived by physical separation from cow milk, buffalo milk, or milk of any other species as defined under this regulation, or a mixture thereof. Cream, with the exception of sterilized variants, is composed of a minimum of 25% milk fat and is derived from cow or buffalo milk or a combination of both. It is a high-energy source that is abundant in fat and fat-soluble vitamins A, D, E, and K. The vitamin content is contingent upon the fat percentage in the cream. 16.2 Classification Cream may be broadly classified into Market cream (direct consumption) and Manufacturing cream (manufacture of dairy products). The three different types of cream are: i. Table cream/Light cream contains 20-25% milk fat. ii. Coffee cream/ Whipping cream Contains 30-40 % milk fat, and iii. Heavy cream/Plastic cream contains 65-85 % milk fat. As per FSSAI Standards, Cream may be labeled according to milk fat content (m/m) along with product name as specified in item 1 of this Standard, as follows: i. Low fat cream: Minimum 10 per cent. and less than 40 per cent.; ii. Medium fat cream: Minimum 40 per cent. and less than 60 per cent.; iii. High fat cream: Minimum 60 per cent.

17.1 Introduction Butter is a fat concentrate that is produced by churning cream to create a solid bulk, which is subsequently processed. The table creamery butter is produced from the cream or coagulate of cows or buffaloes, or a combination of the two. It may contain common salt and natural colorants such as annatto or carotene, but it should be devoid of other animal lipids, wax, mineral oils, and vegetable oils and fats. The only permitted additives are common salt and natural colorants (annatto and carotene), with no preservatives permitted.. The butter must contain a minimum of 80% milk fat, no more than 1.5% curd, and no more than 3% sodium measured by weight. Diacetyl may be incorporated for flavoring purposes; however, it is prohibited from exceeding 4 ppm. Calcium hydroxide, sodium carbonate, and sodium polyphosphate are permissible additives, provided that their combined weight does not exceed 0.2% of the butter’s weight. 17.2 Classification The market supplies a wide variety of butter varieties. This varies depending on the kind of cream used in their production as well as other factors. The varieties of butter are: 1. Pasteurized cream butter: Usually made from sweet cream that has been pasteurised. However, this kind of butter has a milder flavour than the same kind of cream that hasn’t been pasteurised. 2. Ripened cream butter: Butter is produced through adding butter culture to cream and incubating it until the desired acidity and flavour are achieved. Authentically made ripened cream butter possesses a mild flavour commonly known as ‘real butter flavour’. 3. Unripened cream butter: Created from fresh, unripened cream. 4. Salted butter: Butter with added salt. 5. Unsalted butter: Butter without any added salt. 6. Sweet cream butter: Butter made from cream with an acidity level not exceeding 0.2%.

18.1 Introduction Ice cream is produced by freezing a pasteurised mixture that is derived from milk or milk products, with or without nutritive sweeteners and other approved non-dairy constituents, in accordance with FSSAI standards. Except for softserve ice cream, which may remain malleable, this product must freeze solid and may contain air. Ice cream is manufactured using bovine or buffalo milk, cream, or milk products. It may also contain cane sugar, eggs, fruits, fruit juices, preserved fruits, nuts, chocolate, edible flavours, and approved colours. Up to 0.5% by weight of stabilisers and emulsifiers are permissible. The mélange must be heated to the appropriate temperature prior to freezing. A minimum of 10% milk fat, 3.5% protein, and 36% total solids must be present in the product. However, the proportion of milk fat may be reduced to no less than 8% by weight when any of the aforementioned preparations contains fruits, almonds, or both. A declaration to that effect must be included on the label, and starch may be added to a maximum extent of 5%. 18.2 Classification Some of the frozen desserts can be classified as follows. 1. Plain: Plain ice cream has minimal coloring and flavoring, such as vanilla and coffee. 2. Chocolate: Chocolate ice cream is flavored with cocoa or chocolate 3. Fruit: Fruit ice cream contains fruits like strawberry, apricot, pineapple, mango, or banana, which may be fresh, frozen, canned, or preserved. 4. Nut: Nut ice cream includes nuts like almonds, pistachios, walnuts, or cashews, with optional additional flavoring or coloring.

19.1 Introduction Cheese is a product that is produced by coagulating curd from milk with rennet or similar enzymes in the presence of lactic acid produced by adventitious or added microorganisms. Following the shaping of the curd in a mould and the removal of a portion of the moisture, it is permitted to mature by being maintained at an appropriate temperature and humidity for a specified duration.The FSSAI defines cheese as soft, semi-hard, hard, or extra-hard products that are matured or unripened, have a whey protein to casein ratio that is not greater than that of milk, and can be coated with food-grade waxes or polyfilm. coagulating agents. During this procedure, flavor-producing bacteria and harmless lactic acid bacteria may be introduced. The separation of whey is facilitated by the coagulation that results, which also ensures that the cheesemaking process concentrates milk proteins, particularly casein. Consequently, the protein content of cheese is substantially higher than that of the initial milk material blend. Furthermore, cheese-making incorporates methods that result in a final product with comparable physical, chemical, and sensory attributes by coagulating milk proteins or milk-derived products. The ingredients of cheese are limited to those that are naturally present in milk, with the exception of certain additives such as coagulating agents, sodium chloride, and small quantities of calcium chloride, annatto or carotene colourants, and specific emulsifiers and stabilisers such as citric acid, sodium citrate, sodium salts of orthophosphoric acid, and polyphosphoric acid. The wax employed for coating must not present any health hazards, and if it is coloured, it must be made from only approved food colours. The moisture content of hard cheeses is determined by the presence of no less than 42% milk fat and no more than 43% moisture on a dry matter basis. Additionally, they may contain trace quantities of nisin and ascorbic acid or its salts.

20.1 Introduction The average Indian diet, which is predominantly vegetarian, relies heavily on milk as a source of animal protein. Ancient Indians developed more stable milk products to preserve its nutritional value due to the high ambient temperatures in the Indian subcontinent. Therefore, the ethnic dairy foods, which are frequently referred to as traditional or Indian indigenous milk products, have been developed over the course of centuries by utilising locally available equipment, implements, and manufacturing procedures. 20.2 Definition of Traditional Indian Dairy Products Traditional Indian dairy products, or indigenous milk products of India, encompass all milk-based items that have evolved over generations using locally sourced ingredients and traditional cooking methods. With advancements in mechanized manufacturing technologies and unit operations, these diverse indigenous milk products are set to establish a robust presence in the industrial landscape. Across India, a variety of milk-based sweets, beloved by people of all ages and genders, hold significant cultural importance, often being integral to celebrations and social gatherings, highlighting their essential use of indigenous dairy ingredients. 20.3 Classification of Traditional Dairy Products The nomenclature of Indian indigenous milk products varies across different regions due to variations in its components and manufacturing methods. Indigenous milk products can be conveniently categorised into nine main categories to facilitate a deeper understanding of their nature.

21.1 Introduction Khoa, as well as mawa or khava, is a partially dehydrated whole milk product that is produced by perpetually heating milk in a karahi over a direct fire while stirring and scraping it with a khunti until it reaches a semi-solid consistency. The pan is removed from the fire once the desired consistency is obtained, and the contents are transformed into a solid mass known as khoa pat. “Khoa is produced by rapid drying cow, buffalo, goat, or sheep milk, or a combination thereof, and must contain a minimum of 20% milk fat.The product is produced by heat desiccating milk to 65–69% solids in an open pan. Khoa has been utilised as a foundation for Indian desserts for centuries. Milk traders and halwais prepare it according to the conventional procedure. You typically require five times the amount of milk content. 21.2 Classification There are three primary varieties: “pindi” for burfi, “dhap” for gulab jamun, pantooa, and other delicacies, and “danedar” for kalakand. Khoa production has been the most straightforward technique of preserving milk produced in rural areas during the flood season. Pindi, dhap, and Danedar are the three primary varieties of khoa that are prepared throughout the country. Khoa is the foundation for a diverse array of Indian delicacies, such as gulab jamun and other dishes.

22.1 Introduction Chhana is a dairy product that is produced by coagulating milk with acids such as citric or lactic acid at high temperatures, with the whey subsequently drained. Chhana is the term used to describe the curd that is produced as a consequence. It has a distinctive spongy texture, a mildly acidic flavour, and an off-white colour. Chhana is defined as the product that is produced by precipitating bovine or buffalo milk with sour milk, lactic acid, or citric acid, in accordance with FSSAI standards. The milkfat content must not be less than 50.0 percent on dried matter, and it must not contain more than 70.0 percent moisture. This product may also be prepared using milk solids. Low fat chhana shall conform to the following requirements 1. The moisture content should not exceed 70.0 percent. 2. The milk fat content should not exceed 15.0 percent of the dry mass. Additionally, it specifies that such low-fat chhana shall be sold exclusively in sealed packages. Chhana is primarily made from cow’s milk and is utilised in the production of a variety of Bengali sweets. The production of chhana in India consumes roughly 4 to 4.5% of the total milk produced. Sandesh, rasogolla, chamcham, rasomalai, pantoa, and chhana murki are among the numerous desserts that are prepared using chhana as a base.

23.1 Introduction Various products can also be produced by emulsions that contain fat globules. For instance, cream is produced when milk contains concentrated fat. This cream can be further processed to produce butter, ghee, and butteroil. “Milk fat, ghee, butter oil, anhydrous milk fat, and anhydrous butter oil are fatty products that are exclusively derived from milk or products obtained from milk, or both, through processes that result in the almost complete removal of water and milk solids, not fat.” The method of manufacturing (FSSAI standards) has notably influenced the flavour and physical structure of ghee. 23.2 Types of Fat Rich Dairy Products 23.2.1 Cream or Malayi “Cream is a yellowish component of milk that naturally rises to the surface when milk is allowed to stand. It is rich in fat globules.” Cream is mechanically separated in the dairy industry. The size of the fat globules is diminished as a result of homogenisation of cream, which renders the product less suitable for whipping. Cream can be defined as 1. That portion of milk, which is rich in milk fat 2. That portion of milk into which has been gathered and which contains large portion of milk fat 3. When milk fat is concentrated into a fraction of the original milk that portion is called cream.

24.1 Introduction A dairy by-product can be described as a valuable commercial product generated during the production of a primary dairy item. Examples include skim milk, buttermilk, residual ghee, and whey, as depicted in the diagram below. Utilizing these by-products not only enhances plant profitability but also makes essential nutrients accessible to humans while reducing environmental pollution from dairy waste. However, converting these edible substances into non-food items is often unjustifiable, particularly in regions facing milk shortages. Effective management of by-products is crucial for ensuring profitable dairy operations, as every component of milk offers significant nutritional value that should be preserved. Consequently, there is growing global interest among researchers in maximizing the utilization of these by-products. Nonetheless, it’s important to note that while many dairy by-products can technically be processed into useful commodities, feasibility alone does not justify their widespread utilization. If capital and resources are to be assigned to a plan to utilise by-products, their processing must be economically viable. Therefore, it is essential to prioritise the research and development of cost-effective technologies for the improving and utilisation of dairy by-products. A dairy by-product can be described as a commercially valuable product generated during the production of a primary dairy product. Examples include skim milk, buttermilk, ghee residue, and whey, as illustrated in the diagram below. Utilizing these by-products enhances operational efficiency, provides essential nutrients for human consumption, and mitigates environmental pollution from dairy waste. However, converting edible materials into nonfood items may not be justifiable, particularly in regions facing milk shortages. Profitable dairy operations depend significantly on effectively managing by-product disposal. Every component of milk should be processed wisely to preserve its nutritional value. Consequently, there is growing global interest among researchers in optimizing the utilization of these by-products. Nonetheless, while it may be technically feasible to process any dairy byproduct into useful goods, it doesn’t necessarily mean it should be done.

25.1 Introduction Cream, butter, anhydrous milk fat, ghee and fat preserves, cheese, condensed milk, evaporated milk, skim milk, and whole milk powder are among the dairy products that have been extensively examined. 25.2 Defects in market cream In the market, there are a variety of creams, including half cream, single cream, coffee cream, cultured cream, whipping cream, heavy whipping cream, aerosol cream, double cream, clotted cream, and high-fat creams (also referred to as plastic cream). The defects related to market cream are detailed in Annexure-I 1. Flavour defects in cream: Any flavor imperfections originally present in whole milk may become more noticeable in separated cream. Volatile compounds that are fat-soluble tend to concentrate in the fat portion, which can amplify these defects, such as an oxidized taste. Common flavor defects associated with cream include feed, cooked, malty, musty, utensil, weed, acid, bitter, and oxidized/rancid flavors. These flavor defects are further described in the section discussing flavor issues in Table butter. 2. Specific defects in cream • Serum leakage, creaming, reduced overrun in whipping cream: Serum leakage typically results from partial churning (overwhipping), causing an unattractive liquid pool around the whipped cream or sogginess when applied to cakes. Excessive whipping leads to the formation of large fat globule clusters, which can break bubble-enclosing membranes, initiate bubble coalescence, and reduce overrun. This process may lead to an irreversible phase inversion, turning the cream into a greasy water-in-oil emulsion, visible as butter granules. Unfavorable creaming and serum separation can be delayed by lowering fat content (within legal limits), adding stabilizers like carrageenan, emulsifiers, or protein ingredients, or through post-UHT homogenization. Using a mix of kappa and iota carrageenan can help reduce creaming during storage and minimize whipped cream drainage.

26.1 Introduction Developed nations’ packaging sector has achieved great advancement. The advent of innovative marketing strategies such hyper markets and selfservice outlets has pushed the packaging technologies in these nations to unprecedented heights. The evolution of appliances and packaging tools as well as the introduction of fresh and better packaging materials has happened holistically. In nations like India still in development, packaging is still in its infancy. Packaging any product is the arrangement of the most appropriate containers and components to safeguard, move, label, and identify any good. 26.2 Packaging Packaging is putting an item into a protective wrapping or container for use or storage. The package serves three purposes: it stores, shields, and merchandising tool. For the safe delivery of the product through the several phases of manufacturing, storage, transportation, distribution, and marketing, it is a necessary link between the manufacturer and ultimate customer. Fresh, sound and easy form of milk delivery depends on protective packaging to minimise losses and withstand the challenges of climate change, transit, handling etc. 1. To contain the product: The package should be big enough and built with suitable elements to stop spoiling and leaks. It should be sturdy enough to withstand handling, shipping, and storage difficulties as well as closely matched with the product. 2. To protect the product: Packaging seeks to protect the product from microbiological activity, heat, light, moisture, oxygen, evaporation, etc., therefore preventing contamination, loss, damage, or degradation. 3. To help in selling the product: Easy dispensing, reclosure, disposal, and possible reuse should be made possible by the packaging form, therefore helping the marketability of the product.

27.1 Introduction Processed organic food typically consists of solely organic ingredients. If there are any non-organic components, a specified proportion of the food’s plant and animal ingredients must be organic, and any non-organic ingredients must meet specific agricultural standards. Organic foods should not contain artificial additives and are usually processed using fewer synthetic methods and materials, avoiding practices like chemical ripening, food irradiation, and genetic modification. While synthetic pesticides are prohibited, non-synthetic pesticides are permitted. Milk from cows—or any other animal—serves as a useful environmental indicator for measuring pollutants and pesticides because substances consumed by the animal end up in the milk it produces. If contaminants are present in the grass, they will ultimately be found in the milk. 27.2 Beyond these four main factors have led to the increasing interest by farmers and consumers in organic dairy farming 1. Consumer concerns about food safety and animal welfare 2. Overproduction of food (perceived as low in quality) 3. The environmental effects of intensive farming

28.1 Introduction This Act established the Food Safety and Standards Authority of India (FSSAI) to define science-based criteria for food products and control their production, storage, distribution, sale, and import, thereby guaranteeing the availability of safe and nutritious food for humans by aggregating food-related legislation. From the farm to the refrigerator, the FSSAI protects every step to ensure customers all throughout India get milk and milk products free of contamination. The FSSAI has instituted particular rules acknowledging the importance of milk in the Indian diet and the possible health hazards of adulteration or contamination. These criteria cover everything from the quality of dairy farm cleanliness procedures and calf nutrition to processing, packaging, and milk and product distribution. By establishing and following these guidelines, FSSAI not only safeguards the health of millions of people but also fosters consumer trust so that milk and its derivatives may be included into everyday meals. 28.2 The Food Safety and Standards Act Confusion among consumers, traders, producers, and investors results from the several food laws and several authorities in charge of establishing and enforcing standards across several food industries. Different laws provide different standards by including thorough clauses on the admissibility and degrees of food additives, pollutants, colours, preservatives, and other relevant criteria. Many times rigid and out of line with scientific progress and modernism, these criteria also reflect The developing food processing sector is hampered by this diversity of legislation and the participation of several bodies, therefore hindering the efficient creation and execution of food standards.

29.1 Introduction Cleaning is achieved using a cleaning agent designed to remove food, dirt, rust stains, minerals, or other residues. It is crucial to choose the appropriate cleaning agent, as not all are suitable for surfaces that come into contact with food. In a food-processing facility, sanitation involves ensuring that utensils and equipment that come into contact with products are kept clean and sterile. Additionally, clothing, air, packaging materials, and non-contact surfaces like floors, walls, and ceilings must be sanitized to prevent product contamination. Employees’ bodies, especially their hands, can also be sources of contamination, so maintaining high personal hygiene and cleanliness standards is essential. Moisture and heat can lead to microbiological contamination of both products and the environment. Moisture on product-contact surfaces and within products creates a medium where microorganisms can thrive and find nutrients, potentially affecting the safety and quality of milk and dairy products. 29.2 Types of Soil Cleaning involves removing food residues and other types of soil from surfaces like utensils and equipment used in the dairy and food industries. • In the dairy-processing sector, the equipment must be cleaned of various types of soil including: liquid milk films, air-dried films, heatprecipitated films, heat-hardened films, milk stone, and other foreign materials. • Soluble soils will dissolve and be carried away in rinse or wash water. For insoluble soil components, chemical detergents may be needed to either dissolve them or soften them to facilitate easier removal. • Cleaning or sanitizing the product contact surfaces of dairy equipment involves both washing and sterilizing. It’s important to avoid causing undue wear, erosion, or corrosion to these surfaces, as this can reduce their lifespan

30.1 Introduction Every food processing facility, especially those that produce several products, generates trash in various forms. The food products are rich in carbs, proteins, lipids, and mineral salts. During the process of flushing and washing various equipment, nutrients are released into the drainage, promoting the growth of both anaerobic and aerobic bacteria. Consequently, the water that is flushed might have a highly unpleasant smell and could become a challenge for disposal in the municipal sewer system. 30.2 Definition of Waste Management Waste management encompasses the collection, transportation, processing, recycling or disposal, and oversight of waste materials. 30.3 Types of Wastes in a Food Processing Plants Waste produced in food processing plants can be categorized based on their form and origin, whether they are avoidable or unavoidable, their value, or their potential for reuse. 30.3.1 Based on the forms: Wastes based on forms can be classified as 1. Solid wastes, 2. Liquid wastes, 3. Oily wastes, 4. Gaseous wastes/water vapors.

31.1 Introduction A fundamental element of quality assurance is good manufacturing practice (GMP), which ensures that goods are consistently produced and regulated according to the quality standards suitable for their intended application and as outlined by the marketing license. The primary objective of GMP is to mitigate risks in pharmaceutical manufacture, which may be categorised into two main types: erroneous labelling and cross-contamination/mix-ups. Primarily, manufacturers must guarantee that their goods are safe, effective, and of adequate quality; hence, risk assessment has become a crucial component of WHO quality assurance guidelines. 31.2 Implementation of HACCP 31.2.1 HACCP Preamble and Definitions Preamble 1. The introductory portion of this publication delineates the concepts of the Hazard Analysis and Critical Control Point (HACCP) system as endorsed by the Codex Alimentarius Commission. This section provides broad recommendations for system application, recognising that implementation specifics may differ according to the food operation’s unique conditions. 2. The HACCP system, grounded in scientific principles and methodical methodology, identifies specific dangers and implements control measures to assure food safety. It functions as an instrument for hazard evaluation and the implementation of control systems aimed at prevention rather than predominantly on final product testing. The HACCP system is flexible, allowing for modifications in equipment design, processing methods, or technology innovations. 3. HACCP is relevant across the whole food chain, from initial production to ultimate consumption, and its use must be guided by scientific knowledge on dangers to human health. In addition to improving food safety, the use of HACCP can provide other substantial advantages. Furthermore, the use of HACCP systems can streamline regulatory inspections and enhance international trade by increasing confidence in food safety.