eChapters

Laboratory Tests

Sampling procedures

Samples from number of containers- As soon as the cans are received at the reception dock, remove the lid, mix contents of each can with a plunger and draw equal quantities from each container and mix together. Draw approximately 80 – 100 ml of sample for testing. If the cans are of same diameter, Alternatively, milk from different containers are first poured into a vat and then the sample is drawn by thorough mixing as above..

Samples from storage tank – Before drawing sample from storage tank, switch on the mechanical agitator and allow the contents to mix for 15-20 minutes. Discard first 1.0 L of milk. Transfer 250-500 ml of the mixed milk from the outlet valve into a sample bottle.

Samples from rail / road tankers- Open the lid of the tanker and insert a big plunger through the main hole and move it forward, downward and backward bring the plunger to the surface at each stroke. Continue mixing for 15-20 minutes. Draw proportionate quantities of sample with the help of suitable dipper from different levels. Draw 250-500 ml of well-mixed sample into the sample bottle. The total volume of individual composite sample should not be less than 150 ml.

Carbohydrates are the most abundant class of organic compounds found in living organisms. Carbohydrates are also called sugars and are found in plants and animals. Plants synthesize them through photosynthesis (endothermic) by fixing carbon, hydrogen, and oxygen in the presence of solar energy and chlorophyll pigments.
nCO2 + nH2O + energy → CnH2nOn + nO2
Carbohydrates are stored as starch in plants as a source of energy. They are also stored in animals as glycogen in muscles and the liver. They are also found in skeletal structures of cell walls in plants (cellulose), bacteria (peptidoglycans), insects, and crustaceans. This stored food is consumed by animals and man, and upon their oxidation in the body, energy is released for various metabolic activities (work, growth, and various productive functions). Compositionwise, plants are more prosperous in carbohydrates (30%) than animals (1%), with water at 60% and ash at 4%. Plants are poor in proteins (5%) and lipids (1%) as compared to proteins (20%) and lipids (15%) in animals.
2.1 Introduction to Carbohydrates
Carbohydrates or saccharides (sakcharon=sugar or sweetness) are a chemical term applied to a large group of substances, which are organic compounds containing elements Carbon, Hydrogen, and Oxygen in a ratio of 1:2:1. Hydrogen and Oxygen atoms are in the ratio of two to one as in water molecules. As the ratio of hydrogen to oxygen is like H2O, they are also known as “hydrates of carbon” and are represented as (CH2O)n. But there is an exception to this general formula. Deoxyribose (C5H1OO4) and rhamnose (C6H12O5) do not have the required ratio of 2:1 for hydrogen to oxygen. On the other side, some compounds possess this required ratio but are not carbohydrates, e.g., formaldehyde (CH2O), acetic acid (C2H4O2), and lactic acid (C3H6O3). Further, some carbohydrates have nitrogen(glucosamine), phosphorus, and sulfur but do not satisfy the above general formula. The simplest sugars are called monosugars or monosaccharides. There are two main functional groups in

Cheese is made from milk, with the addition of cream, buttermilk, and/or whey. This basic raw material is also called cheese milk. Cheese consists mainly of casein (the major protein of milk), other milk proteins, fat, other milk components, and a certain percentage of water, which is bound. Proteins are precipitated by enzymes and/or acidification as well as heat and are separated by suitable processes from the aqueous phase. (whey, serum). Cheese is most often molded, pressed, and salted and has fungal and bacterial culture additions. colorants, herbs, spices, and other non-dairy ingredients are also added to the cheese. It is consumed either fresh or at different stages of ripening.

Worldwide, there are more than 2000 types of cheese, sometimes made by very different manufacturing processes. A classification can be based on several aspects and is done in different countries according to different criteria. A general classification can be made for three major groups:

a. Rennet or natural cheese: manufactured straight from milk by using proteolytic enzymes (rennet) and acid, with a more or less pronounced ripening process.

b. Fresh cheese or non-ripened Cheese: Quarg, fresh cheese, and white cheese are examples. Its manufacturing process is similar to that of rennet cheese manufacturing, but it has a high degree of acidity and is not subjected to a proteolytic ripening process.

c. Long-life cheese (processed cheese): it is more often made from rennet cheese and is textured by thermal treatment and made shelf-stable.

Concentrated milk products are obtained through partial removal of water which increases the dry matter content of milk. The increase in dry matter content in concentrated milk is proportional to the degree of concentration. The milk concentrate may be prepared from either full-cream whole milk or fat-free skim milk.

Depending on the nature of raw material and other non-milk additives concentrated milks are classified into four broad categories.

1. Sweetened condensed milk

2. Evaporated milk or unsweetened condensed milk

3. Sterile milk concentrate

4. Reconstituted concentrated milk

Sweetened Condensed Milk

One of the earliest dairy products to be produced industrially is sweetened condensed milk. According to FSSA (2006), sweetened condensed milk is the product obtained by partial removal of water from the milk of cow/buffalo with the addition of sugar or a combination of sucrose with other sugars or by any other process that leads to a product of the same composition and characteristics. The fat and/or protein content of the milk may be adjusted by the addition and/or withdrawal of milk constituents in such a way as not to alter the whey protein to casein ratio of the milk being adjusted. It shall have a pleasant taste and flavor and be free from off-flavor and rancidity. It shall be free from any substance foreign to milk. It may contain food additives. It shall conform to the microbiological requirement as laid down by FSSA. The said product shall also conform to the following requirements

1.1 Introduction
Concentrated milks, like evaporated milk and sweetened condensed milk, serve as practical substitutes for fresh milk in regions where access to it is limited or where transportation and storage are challenging. These products go through specific processing techniques to reduce their water content, thereby improving their shelf life and transportability. Evaporated milk is created by removing water through evaporation and then
sterilizing it to prevent microbial growth. This process results in a thicker consistency and a slightly caramelized flavor due to the heat treatment. On the other hand, sweetened condensed milk is made by adding a significant amount of sucrose to the milk and excluding oxygen, which inhibits microbial growth. This results in a thick, sweet product suitable for various culinary uses. These concentrated milk products are usually packaged in small cans, making them convenient for storage and transportation. However, they are sometimes diluted before consumption with water to resemble the taste and consistency of fresh milk. In regions where even concentrated milks are not easily accessible, alternatives like whole milk powder or recombined milk are used. These alternatives involve dehydrating milk into powder form or reconstituting milk components to create a liquid similar to fresh milk. Innovations in processing and packaging have led to the development of alternative uses for concentrated milks, expanding their versatility beyond traditional applications. These products continue to provide essential dairy
nutrition in areas where fresh milk is scarce or hard to obtain, offering a shelfstable solution to meet dietary needs.

Chemistry of Creaming

After being drawn from animals, normal milk will form a cream layer on standing. Because of the difference in density between fat globules (920 kg m−3 at room temperature) and milk plasma (density 1030 kg m−3), the granules tend to rise. This causes creaming, which we often want to prevent and it enables milk to be separated into cream and skim milk. Creaming is much enhanced when the globules have been aggregated into flocculates, clusters, or granules.

Cream Ripening

This unit operation serves as an intensive preparation of the cream for the churning process. It is divided into two categories.

1. Physical ripening;

2. biochemical ripening The following criteria are influenced by the cream ripening:

• Consistency, firmness, and spreadability of butter.

• Basic water content of butter during the manufacturing process (bound water in butter, which cannot be removed by any mechanical treatment).

• Buttermilk fat content, which has to be minimized.

The melting and solidification behavior of fat depends on the attached fatty acid, which indicate the hardness of the butterfat.

Natural hardness is caused mainly by seasonal feeding of the milk animals. Winter feed with a great deal of dry feed or roughage yields a hard butterfat with a high percentage of saturated and short-chain fatty acids and few double bonds in the fat molecules.

Summer feeding (green grass) results in fat with longer chains and a higher percentage of unsaturated fatty acids with many double bonds. We therefore distinguish between summer fat and winter fat or summer cream and winter cream.

The process of making dried milk involves eliminating water from milk, primarily through spray or roller drying. It is regarded as a significant sector of the dairy industry and is made from whole cow, buffalo, or standardized milk. Skim milk powder (SMP) is made from milk after the fat has been removed whereas whole milk powder (WMP) is made from whole cow or buffalo milk

FSSA (2006) Standard Of Milk Powder According to FSSA (2006), Milk powder is the product obtained by partial removal of water from the milk of cows and/or buffalo. The fat and/or protein content of the milk may be adjusted by the addition and/or withdrawal of milk constituents in such a way as not to alter the whey protein to casein ratio of the milk. It shall be of uniform color and shall have pleasant taste and flavor, free from off-flavor and rancidity. It shall also be free from vegetable oil/fat, mineral oil, thickening agents, added flavor, and sweetening agents. It may contain food additives. It shall conform to the microbiological requirements prescribed by FSSA (2006).

Water activity, high storage temperatures, longer than usual storage times, high product moisture content, high processing temperatures, and container headspace are some of the variables that affect the Maillard reaction in dried milk.

Casein and whey proteins are the major proteins present in milk. Unlike casein, whey proteins are heat-labile. Whey protein fractions present in milk are α-lactalbumin, β-lactoglobulin, bovine serum albumin, immunoglobulin, euglobulin, and lactoferrin. β-lactoglobulin and κ-casein interact during heat treatment. When milk is refrigerated for longer than 24 h, it forms γ-casein and protease-peptone fractions.

2.1 Introduction
The continuous production of dry milk has become consistently significant within the dairy industry and is expected to continue growing due to its advantageous features. These include improved shelf life, reduced storage
requirements, and lower transportation costs, all of which contribute to favourable economic outcomes.
For example, non-fat dry milk is also known as skim milk powder, dried skim milk, non-fat dry milk solids, or dehydrated skim milk. Similarly, products like dried whole milk, dried cream, and dried buttermilk are often regarded as dried or powdered whole milk, cream, and buttermilk, respectively, based on their specific compositions.
2.2 Types of Dried Powder
1. Nonfat dry milk
2. Dry whole milk
3. Dry buttermilk
4. Dry whey
5. Dry ice cream mix
6. Dry creams (sweet or sour)
7. Dry skim milk vegetable fat products
8. Malted milk Powder
9. Cheese powders (Cheddar, Blue, etc.)
10. Sweetened chocolate flavoured non fat dry milk
11. Coffee creaming products
12. Sodium or Calcium Caseinates
13. Dry high acid milks
14. Partly skim milk powder
15. Infant milk food

The terms “cultured dairy foods,” “cultured dairy products,” and “cultured milk products” are other terms for fermented dairy products. Lactobacillus, Lactococcus, Leuconostoc, and other lactic acid bacteria, along with yeasts in certain products, are used to ferment milk to make these dairy products. The product’s shelf life is extended through fermentation, which also improves the product’s taste and milk’s digestibility. There is a wide variety of fermented milk products available, each with unique flavors and attributes. The following categories apply to fermented milk products, based on the type of fermentation.

Changes in Nutrients Resulting from Fermentation

Fermentation lowers the lactose content in fermented milk products; however, if the starting milk is concentrated or fortified, the finished product’s lactose content may be higher than that of liquid milk.

The composition and content of protein and total amino acids are comparable to those of raw milk. Casein degradation is small compared to cheese, accounting for not more than 1% of the total protein. While some products of casein degradation are used by the starter microorganisms, others build up as free amino acids in the fermented kinds of milk. The amounts of free amino acids that build up differ depending on the species. Generally, proline is increased in large quantities, followed by serine, alanine, valine, leucine, and histidine. As a result of continuous starter culture activity, the level of free amino acids increases during storage. A limited degree of lipolysis occurs during the manufacture of fermented milk. The amount varies depending on the type of species, but the pattern and concentration of free fatty acids are both impacted. During fermentation and the breakdown of amino acids, trace amounts of volatile fatty acids are also produced.

One of the most consumed and well- known milk products in the Indian subcontinent is ghee. It is a by- product of tradition, prepared both at organized dairy plants and the household level for a well- established market. Ghee is traditionally made from the milk of cows or buffalo. The tetrapyrrole pigments biliverdin and bilirubin are responsible for the distinctive color of buffalo ghee. On the other hand, ghee is golden yellow due to the presence of carotenoids in cow’s milk. Ghee’s composition changes according to the kind and feeding habits of the animal and can differ from place to place and season to season.

In addition to, being a substantial source of fat- soluble vitamins, essential fatty acids, and other growth- promoting components, ghee is a rich source of energy. Its value as food for humans is enormous. Additional attributes related to medicine are present in ghee. Ghee can improve one’s physical and mental attributes and treat eye conditions like ulcers. Ghee is used in religious and ceremonial rites in addition to being consumed.

Composition

Ghee is a complex lipid composed of mixed glyceride which makes up 99–99.5% of its total content. In addition, it has trace amounts of calcium, magnesium, phosphorus, iron, copper, and fat- soluble vitamins, tocopherols, carbonyls, hydrocarbons, carotenoids, free fatty acids, phospholipid, sterols, and sterol esters

4.1 Introduction
Human milk widely acknowledged as the optimal source of nutrition for infants, providing a rich array of components crucial for their growth, repair and development. However, the composition of human milk can vary
significantly within and between feeds, throughout the day, over the course of lactation, and among different mothers and also populations. While this variability is beneficial for infant health and survival, it presents challenges for the management of nutrition of high-risk infants who require precise oversight. The composition of human milk can be altered by factors such as the handling of expressed milk, including how it is stored and pasteurized. Thus, proper management of expressed milk is essential. The recommended practice for infant nutrition is exclusive breastfeeding for the first six months, followed by continued breastfeeding for at least one to two years. Human milk is naturally suited to meet the nutritional needs of infants, providing both nourishment and bioactive compounds that support healthy growth and immunity.
Human milk contains a variety of bioactive components, such as immune cells, anti-infective and anti-inflammatory agents, growth factors, and prebiotics. In contrast to infant formula, which has a fixed nutritional profile, human milk is dynamic and can vary between and within feedings, influenced by maternal factors, environmental conditions, and the methods used for expressing and managing milk.
A thorough understanding of human milk’s composition is vital for effective infant feeding, especially for at-risk infants. It also allows for the assessment of how milk storage and pasteurization may impact its beneficial components. Additionally, some of the bioactive elements in human milk are being studied for their potential use in medical treatments, either as preventive or therapeutic agents.

Commercially, one of the most significant milk products is ice cream. It is a frozen product which is usually made from milk or cream that has been f lavored with fruits like peaches or strawberries, and spices like vanilla or cocoa, or with sugar or a substitute. Stabilizers are sometimes combined with food coloring. Ice cream mix typically contains 10.0% milk fat, 11.0% solids not-fat, 14.0% added sugar, and 0.3% additives like an emulsifier, stabilizer, f lavor, and color substances.

Standard of Ice Cream

According to FSSA (2006), ice cream, kulfi, chocolate ice cream or softy ice cream means the product obtained by freezing pasteurized milk prepared from milk and/or other products derived from milk with the addition of sweetening agents and fruit products, egg products, coffee, cocoa, ginger, and nuts. It may also contain chocolate, and bakery products such as cake or cookies as a separate layer and/or coating. It may be frozen hard or frozen to a soft consistency. It shall be free from artificial sweeteners. It shall have a pleasant taste and smell free from flavor and rancidity. It may contain food additives. It shall conform to the microbiological requirements as given in FSSA (2006).

3.1 Malted Milk
Malted milk, originating from the ideas of British pharmacist James Horlick in the 19th century, was initially marketed under the name “Diastoid” before being trademarked as “malted milk” in 1887. Although initially targeted
for infants and invalids, its appeal expanded due to its nutritional value, convenience, digestibility, and palatability. Recognized globally for its lightweight, non-perishable nature, and high-calorie content, malted milk is
created by evaporating a mixture of malted barley, wheat flour, and whole milk until it forms a powder.
There aremainly two types of malt powder: diastatic and non-diastatic. Diastatic malt containing enzymes breaking down starch into sugar, aiding in dough rise and crust formation, particularly in bread making. Non-diastatic
malt lacks active enzymes and is primarily utilized for flavor enhancement, commonly in beverages. It may also include sugar, coloring agents, and other additives to improve taste and appearance.
3.2 Malting
Malting is a crucial process employed in treating cereal grains, such as barley, by inducing germination through soaking in water followed by halting the process through drying or heating with hot air. This technique encompasses two main stages: sprouting and kiln-drying. The term “malt” encompasses several products of this process:
1. Malted grains: These are grains, like barley, that have undergone the malting process.
2. Malt sugars: These are sugars, predominantly maltose-rich, derived from malted grains, often utilized in baking, such as baker’s malt.
3. Malted milk products: These include beverages like malted milkshakes, made using malted milk.

Being an essential component of the rich Indian past, traditional dairy products and a sophisticated classification of confections have played a significant role in the Indian economy. Depending on how it is processed, it has significant social, cultural, and economic significance. These products have been developed over a long period using a combination of experience, traditional wisdom, and culinary skills. India is emerging as the highest milk- producing country in the world with an annual production of 221.1 million tons in the year 2021–22 (Source: Basic Animal Husbandry Statistics, MoFAHD, DAHD, GoI). An estimated 50% of the milk produced in India is used to make a range of traditional dairy products, including paneer, dahi, ghee, khoa, and shrikhand. The product is not only well- established in the Indian market, but it also has significant export potential due to the large Indian diaspora living all over the world.

All native milk products that have developed over time using locally accessible technologies are referred to as traditional Indian dairy products or Indian indigenous milk products. The Indian masses’ economic, social, religious, and nutritional well- being are greatly influenced by traditional dairy products.

Classification of Traditional Indian Dairy Products

Traditional dairy products in India are typically made, packaged, and/or sold using time- honored methods without the use of machinery or meticulous documentation of the procedure. These products do, however, have several technological advantages, including their widespread appeal, reduced cost of production, straightforward manufacturing process, adoption at the rural level or collection center, large profit margin, and abundance of employment opportunities. These products are categorized according to the manufacturing principle.

Milk is the secretion of the mammary glands of animals. For human consumption, milk is that liquid obtained from the cow or the buffalo during the period following at least 72 hours after calving or until the milk is colostrums-free. It is a complex biological fluid consisting of seven main components: water, fat, protein, sugar (lactose), minerals, vitamins and enzymes. Milk is a white opaque fluid in which fat is present as an emulsion, protein and some mineral matters in colloidal suspension and lactose together with some minerals and soluble proteins in true solution. The opacity of milk is due to its content of suspended particles of fat, proteins and certain minerals. The colour varies from white to yellow depending on the carotene content of the fat. Skimmed milk is more transparent with a slightly bluish tinge. Milk of a good flavour has a pleasant, slightly sweet taste, and no odour. It is an excellent source of calcium, phosphorous and riboflavin. Vitamin A and D are currently added to whole milk, partly skimmed and skimmed milk.

Abstract

Chitin has been ranked at second position after cellulose as the most abundant natural biopolymer. Chitin has similar chemical structure to that of cellulose with 2-acetamido-2-deoxy-b-d-glucose (NAG) monomers attached via ß (1–>4) linkages. Chitosan is the deacetylated (to varying degrees) form of chitin, which, unlike chitin, is soluble in acidic solutions. Therefore, Chitosan, a copolymer of glucosamine and N-acetyl glucosamine, is amongst the most copious biopolymers on earth and finds wide range of biomedical and industrial applications. It has been approved in 1983 by USDA as a feed additive. Chitin basically is obtained from prawn/crab shells and chemical treatment of chitin produces chitosan. Since supplies of seafood waste are seasonable and variable, so fungi can be used as alternative source for chitosan. The unique physicochemical properties of chitosan provide great potential of its utilization in food industry especially dairy industry such as production of dairy products, dairy waste water treatment, extension of shelf life of dairy products etc. In recent years, exotic synthetic compounds are losing their appeal, thus application of chitinous products in dairy as well as processing aids has received considerable attention. The modified chitosan with greater functional properties has increased application in different dairy foods. This chapter focuses on the fundamental uses of chitosan and their derivatives in a variety of dairy industry applications.

Chocolate is almost unique as a food in that it is solid at normal room temperatures yet melts easily within the mouth. This is because the main fat in it, which is called cocoa butter, is essentially solid at temperatures below 25^oC when it holds all the solid sugar and cocoa particles together. This fat is, however, almost entirely liquid at body temperature, enabling the particles to flow past one another, so the chocolate becomes a smooth liquid when it is heated in the mouth. Chocolate also has a sweet taste that is attractive to most people.

The first known cocoa plantations were established by the Maya in the lowlands of south Yucatan about 600 AD. Cocoa trees were being grown by the Aztecs of Mexico and the Incas of Peru when the Europeans discovered central America. The beans were highly prized and used as money as well as to produce a drink known as chocolatl. The beans were roasted in earthenware pots and crushed between stones, sometimes using decorated heated tables and mill stones, similar to those illustrated in Figure 1.1.

The development of a recipe for chocolate should be based on three criteria:

(i) The intended market or use;

(ii) The limitation being placed on material and production costs;

(iii) The desired quality.

The amount of fat present in the chocolate will affect the flow properties, and fat content must therefore be varied according to the intended use.

Some point to remember while manufacturing chocolate:

1. To maintain proper viscosity if fat content is increased then sugar content should also be increased.
2. Milk chocolate requires lower fat content than dark chocolate.
3. Addition of emulsifier like commercial lecithin can save upto 5% of added cocoa butter.

Weaning foods

Introduction

Breast milk is natural and best for the growth and development of newborn babies. Although breast milk is adequate to provide an optimum nutrient till the age of six months but after that it is not sufficient to sustain optimum growth and fulfill their nutritional requirements. Various nutrients are required to supplement milk until child is ready to eat adult meal. This additional food along with the breast milk is referred as “complementary Food”. With adequate amount of complementary feeding breast-feeding continues up to two years of age and beyond so, referred as complementary feeding period.

Appropriate and adequate amount of complementary feeding helps in preventing malnutrition stunting and promoting growth. Introduction of this complementary food is called as weaning.

Weaning is the process of introducing adult food and beverage to the infant to support their growth and development. This is very crucial period in infant’s life. This is a period for diet transition as the nutrition requirements for growth and brain development is quite high. Introduction of various taste and texture promotes biting and chewing skills (Guthrie, 1975). Most six-month age children start eating semisolid foods. Weaning homogenized infant foods play a major role in the nutrition of infants (Martinez, 2004).As infants grow, their nutritional requirements also increase. To keep up this growing demand WHO recommends that infants start eating solid, semi-solid or soft foods at the age of 6 months to ensure sufficient nutrient intake.

Abstract

Classification of the hundreds of possible dryers is essential to the logical selection of appropriate dryer for a given application. Diverse criteria for classification as well as selection of dryers are presented and discussed briefly. The advantages and limitations of different dryer types must be taken into consideration. Initial capital cost is often the key deciding criterion in industrial dryer selection. This is not a good strategy as the user must pay for the operating costs over a long period of life of the dryer. In general several different dryer types are suitable for a given product. Careful selection is essential for cost-effective operation of the dryer.

LAB constitutes a group of gram positive bacteria. They are nonsporulating, nonrespiring but aerotolerant cocci or rods, which produce lactic acid as one of the main fermentation products of carbohydrates, they do not have cytochromes. They belong to the phylum Firmicuttes, class Bacilli and order Lactobacillaceae. The group includes several genera such as Lactobacillus, Lactococcus, Bifidobacterium, Pediococcus, Enterobacter, Corynebacterium, Streptococcus, Leuconostoc etc.

Fruits and vegetables are more perishable and generally have a higher value compared to cereals, making them very important in terms of minimizing waste and improving employability in the food industry. The losses in fruits and vegetables are significant, but through effective post-harvest processing, these losses can be reduced, and surplus produce can be better utilized. This processing involves a variety of techniques that prepare fruits and vegetables for conversion into processed foods. The food preservation and processing industry has evolved from being a luxury to an essential sector, playing a crucial role in conserving and enhancing the utilization of fruits and vegetables. To prevent waste during peak seasons and ensure availability during off-seasons, modern methods of storage and processing are necessary. These techniques allow for both large-scale and small-scale processing, extending the shelf life of produce for better distribution. The ultimate goal of food processing is to apply systematic techniques to preserve, process, package, store, and distribute food in a way that ensures a steady supply of diverse and nutritious food options, thereby improving food intake and nutritional standards, particularly during periods of low availability.
For effective preservation and processing, key prerequisites include cleaning, grading, and sorting the produce based on its maturity level. This ensures that only the highest quality fruits and vegetables are used in the processing chain, maintaining food safety, nutritional value, and consumer acceptability throughout the year.
CLEANING OF AGRICULTURAL COMMODITIES
Blanching is a unit operation used in food processing to remove contaminating materials from food and prepare the surface for further processing. In vegetable processing, blanching serves the additional purpose of cleaning the product. This process involves briefly exposing the food to heat, typically by immersing it in hot water or steam, which helps to remove dirt, enzymes, and microbial contamination. By doing so, blanching not only improves the quality of the food but also prevents microbial growth during storage or delays in processing. This early removal of contaminants ensures that the remaining bulk of food is preserved and remains safe for consumption throughout its shelf life.

There is no single factor as important in the production of fine quality dairy products as absolute and complete cleanliness.

R.B. Barrett

It is not enough to provide milk for man, it must be high quality milk. It would be impossible to provide man with milk and milk products of superior quality if we were unable to remove milk soil and to kill residual microorganisms. Respectively, these are the processes of cleaning and sanitizing.

To successfully provide the atmosphere for proper food safety, the basics must be thoroughly understood. The basics of food safety begin with good understanding of sanitation processes, food-handling procedures that protect from, or eliminate cross contamination problems and specific attention to inspection of and follow up for all processes. Food safety activities need to be programmed into available time of day scheduling just as production requirements do. Whether special personnel or separate shifts handle cleaning responsibilities or you clean as you go on the production line, time must be made available. Safe products leaving the facility must be the watch word of all employees involved with the process.

In order to ensure safe food supply a high level of sanitation should be maintained throughout the food production chain. The word ‘sanitation’ is derived from the Latin word “sanitas” which means “health”. To further apply this word to the food industry, sanitation is the creation and maintenance of hygienic and healthful conditions when processing, preparing and handling food. Sanitation is the application of science to provide wholesome food handled in a hygienic environment by healthy food handlers to prevent contamination by food spoilage microorganisms. Effective sanitation refers to the mechanisms, which accomplish these goals.

Cleaning and sanitisation are the two processes employed in dairy industry to ensure hygiene and product safety. The safety of milk and milk products is a very important aspect and every attempt should be made, during processing, to minimize contamination through handling and processing equipments. The accumulated dried milk solids (milk stones) consist largely of calcium phosphate, milk proteins (precipitated, coagulated and baked on by heat) and insoluble calcium salts from water and washing detergents. The surface can also contain biofilms, which are formed by the incorporation of bacteria into the accumulated inorganic and organic materials that attach to most surfaces. With time and in the presence of nutrients, a biofilm and the bacteria within the biofilm will grow and become strongly attached to the surface. The removal of dairy soil, milk stones as well biofilms is the prime objective of the cleaning process. International Dairy Federation (IDF) defines a clean surface as one which is free from residual film or soil that will not contaminate the food products coming in contact with it.

While cleaning refers to the removal of soil from the surface of the equipment, sanitisation implies destruction of all pathogenic and almost all non-pathogenic organisms. Cleaning and sanitisation are complimentary processes. Either of the processes alone will not achieve the desired result, which is to leave the surface as free as possible from soil and viable organisms. In actual practice cleaning and sanitisation overlap to some extent, as during cleaning a high proportion of bacteria are destroyed and others get removed in the detergent solution. Inadequate or faulty cleaning and sanitisation can have serious consequences, as milk is a prefect nutrient in which bacteria can multiply. A thorough understanding of the cleaning methods is, therefore, necessary for economic production of high quality food products.

Cleaning and sanitizing of dairy plants is essential for providing safe milk products to the consumers as well as for ensuring the good shelf life of these products. It ensures cleanliness, hygiene of the equipments and surroundings and also ensures that the products meet the safety standards. Cleaning of dairy plant consists of broadly of removing the soil from the surface of the equipment by dissolving or suspending the soil in a warm solution of suitable cleaning agents. In the dairy industry, the soil is primarily milk and milk product residues which may be more or less modified by processing treatment. 
Milk and milk product residues are complex mixtures of milk sugar, fat, proteins and mineral salts. Some of these solids are present in emulsion, some are in a colloidal state, and others are in true solution. When milk products are heated in vats or pumped through sanitary pipe lines or over coolers, the metal or glass surfaces become coated with milk remains, which, if allowed to dry, may be difficult to remove.

Cleaning and sanitation are essential for maintaining microbiological safety in ice cream manufacturing, particularly because contamination can occur after pasteurization and freezing does not eliminate all microorganisms. This chapter explains contamination routes, hygienic zoning, cleaning systems, sanitization practices, HACCP principles, and microbiological expectations within an ice cream plant. It examines CIP and COP systems, detergent components, cleaning factors, high-risk equipment and surfaces, and post-pasteurization contamination control. Particular emphasis is placed on preventing biofilms and controlling contamination at filling equipment, tanks, pipelines, feeders, drains, packaging areas, and personnel interfaces. The chapter provides practical sanitation guidance to support food safety, product stability, regulatory compliance, and consumer protection

Dried Cocoa Bean have chemical composition as: The shell (testa) represents 10-14% dry weight of the cocoa bean, while the kernel or cotyledon is made up of most of the remaining 86-90%. The cotyledon confers characteristic flavours and aromas of chocolate and is composed of two types of parenchyma storage cells.

Before processing, the quality ofbeans is evaluated for the following indicators:

1. Degree of fermentation
2. Moisture content (maximum 6%)
3. Number of defects
4. Number of broken beans
5. Bean count (number per 100 g)

Cocoa butter, also called the obroma oil, is a pale-yellow, edible fat extracted from the cocoa bean. It is used to make chocolate, as well as some ointments, toiletries, and pharmaceuticals. Cocoa butter has a cocoa flavor and aroma. Its melting point is just below human body temperature. Cocoa butter that has been refined by neutralization with an alkaline solution and decoloured with for example bentonite, activated carbon etc. Subsequent deodorization can also be applied. The type of process used may affect the quality of the cocoa butter. For example, a too high deodorization temperature or a too severe alkalization can completely alter its setting (solidification) characteristics. High-quality raw materials are needed to make the best quality cocoa butter. The other important factors for high quality are the origin of the beans and the processing conditions used. Press cocoa butter, which is most commonly used in the chocolate industry, is only filtered and (partly) deodorized to obtain the desired flavour. Cocoa butter contains a high proportion of saturated fats as well as monounsaturated oleic acid, which typically occurs in each triglyceride.

Introduction

Botanical name of cocoa is Theobroma cacao and family is Malvaceae. The cocoa bean, also cacao bean or simply cocoa or cacao, is the dried and fully fermented fatty seed of Theobroma cacao, from which cocoa solids and cocoa butter are extracted. Cocoa flavour is the most distinct feature of chocolate, thus cocoa beans are the basis of chocolate. Dried cocoa beans are usually processed into cocoa butter, which contains fat between 56% and 58%, made up of a mixture of triglycerides. Cocoa butter with this composition is good for making chocolate and has favourable hardness and a melting point of body temperature. Theobroma cacao originated from the Jungle of the Amazon in Brazil. Theobroma cacao consists of two subspecies: the Cacao, a subspecies known as the Criollo, which can be found in Central and South America, and spharocarpum, which is also called theForastero. The Criollo has superior and fine flavour. The pods are red and the beans have no color. Forastero has a green pod

Thermal heating methods are used from long time to decontaminate the food products from microorganism and therefore increase its shelf life and ultimately make the product safe for human consumption. But these methods diminish the sensory, physicochemical and nutritional properties of food (Barba et al., 2012). Also, the cost of generation of heat in manufacture of food product make the product costlier in thermal processing and also create environmental issue.

Introduction
Similar to the procurement of raw materials in a factory, milk collection is one of the initial and essential steps for a milk processing or marketing company. A successful milk collection system combines efficient route planning, quality control, and effective farmer engagement. By prioritizing technology integration, cold chain management, and regulatory compliance, dairy companies can establish a reliable and sustainable milk procurement system that meets both operational and quality standards.
India dairy sector depends on smallholder individual milk producers, each contributing between one to a few litres of milk per day. Typically, milk production takes place in rural areas, while the demand is concentrated in urban centres. However, rural producers often face significant marketing challenges due to the dispersed nature of milk production, scattered settlements, and inadequate supply infrastructure. Therefore, milk needs to be collected, transported, and marketed from villages to cities to ensure profitable returns for producers. Milk is usually collected from producers at designated collection points in rural areas, which serve a large number of small suppliers. This approach minimizes the need for individual chilling and storage facilities. Collection points should follow the same hygiene standards as dairy processing facilities. Milk should arrive at a chilling station within four hours of milking, especially in warmer climates. There, it must be quickly cooled to below 4°C to preserve its quality. Bulk milk coolers of required capacity are installed for the chilling and storage of milk at low temperature till it is transported to the processing plant.

Introduction

Dairy is vital to the economics of many developing countries. Animals are a source of food, more specifically protein for human diets, income, employment and possibly foreign exchange. For low income producers, dairy can serve as a store of wealth; provide draught power and organic fertilizer for crop production and a means of transport. Consumption of dairy and dairy products in developing countries, though starting from a low base, is growing rapidly. Dairying has become an important secondary source of income for millions of rural families and has assumed a most important role in providing employment and income generating opportunity. Indian Dairying is unique in more than one ways. It ranks first with its 199.1 million cattle & 105.3 million buffaloes accounting for about 51 percent of Asia’s and about 19 per cent of world’s bovine population. It also ranks first in milk production with a production of 121.8 million tones in 2010-11 and the demand is expected to be 180 million tones by 2020. To achieve this demand annual growth rate in milk production has to be increased from the present 2.5 % to 5%. Thus, there is a tremendous scope/potential for increasing the milk production through profitable dairy farming. Besides milk, the manure from animals provides a good source of organic matter for improving soil fertility and crop yields.

Chocolate is a key ingredient in many foods such as milk shakes, candy bars, cookies and cereals. It is ranked as one of the most favourite flavours in North America and Europe. Despite its popularity, most people do not know the unique or igins of this popular treat. Chocolate is a product that requires complex procedures to produce. The process involves harvesting coca, refining coca to cocoa beans, and shipping the cocoa beans to the manufacturing factory for cleaning, conching and grinding. These cocoa beans will then be imported or exported to other countries and be transformed into different type of chocolate products.

In history, 1828 marked the “modern era” of chocolate making when Dutch chocolate maker Conrad J. van Houten patented an inexpensive method for pressing the fat from roasted cacao beans along with other processes to create a fine powder known as “cocoa”. The powder was then treated with alkaline salt that helped the powder mix with water easily. The creation of powdered chocolate made it easier to mix with water, sugar and a possible combination of other ingredients to make chocolate in solid form. Many other chocolate makers began to build on Van Houten’s success to make a variety of chocolate products. In 1894, English chocolate maker Joseph Storrs Fry produced what was arguably the world’s first eating chocolate”

Milk, on reception at the dairy factory is subjected to various unit operations on its way to product manufacture. Processing is applied as a means to convert liquid milk into products or to render the milk (and products) safe from harmful organisms. The basic processing operations to which milk is subjected at processing units have been described in this chapter. The common processing operations employed are depicted in Fig. 4.1. Several of these operations are routine compulsory processes common to all dairies, while certain others are undertaken for specialized purposes in some dairies.

4.1. Filtration and Clarification

At the time of milking various foreign materials such as dirt, feed, manure, dandruff, hair, flies, dust particles, worn out cells, cell debris and many other undesirable substances may find their way into milk. The process of removal of this extraneous matter (solid particles of higher density than that of milk) is called filtration or clarification. This can be achieved either by simple filtration through specially woven filter cloth or continuous process of centrifugal clarification that helps

1.1. Introduction

A typical dairy farm consist of different classes of dairy animals like calf, heifer, breeding heifer, pregnant, milch and dry animals and bull. The systems of management for the different classes are not same. They need some routine as well as periodical farm practices, some of which are common for all categories of animals (i.e., identification, dehorning, grooming etc.), while some categories need special farm operations (e.g., castration in males, milking etc.). Also there is need of routine disinfection of animal sheds and farm premises to prevent and control occurrence of diseases and maintaining the animals healthy. Further for proper execution of all these operations there is need of keeping farm records.  Keeping in view the above points, this section deals with some important farm management practices.

Introduction

Fermentation is the process in which edible microorganisms invade food substrates and convert them into fermented foods including beverages, using their enzymatic and metabolic processes. These end products will have nontoxic flavors, aroma and texture which enhance the palatability. The word “fermentation” is originated from a Latin word fermentare, defined as “to leaven” (Frias et al., 2016). It is one of the oldest food processing technologies used by humans to preserve perishable food materials for long time, dated back to ancient human civilization (Hutkins, 2008). Globally, more than 5000 varieties of fermented foods are currently in use which includes traditionally fermented dairy products such as Dahi in India to industrial production of wines from fruits (Tamang, 2010) (Table 1 and Figure 1). Biochemically, fermentation is a metabolic process in which energy is derived from organic compounds without the involvement of an exogenous oxidizing agent. Fermentation may result in the production of many by-products such as carbon dioxide, alcohol, organic acids (lactic acid, acetic acid), vitamins, enzymes etc. which are now having more importance in food industries (Caplice and Fitzgerald 1999).

Abstract

Food dehydration is an oldest method to increase the shelf life of food by reducing the water activity. A dried food product provides advantages of increased shelf life and reduced cost due to decreased weight as well as transportation. However, there is a decrease in product quality due to inadequate control on drying process parameters such as drying temperature and moisture removal together with change in thermo-physical properties of food. Computational modeling and simulations can provide a unique insight on the drying parameters that influences the product quality, and optimize the process conditions which are difficult by experimental analysis. Moreover, the computational techniques are advantageous over experimental optimization methods by minimizing the time and cost. This chapter reviews different computational modeling techniques such as, finite element modeling, finite volume and finite difference methods for modeling of food dehydration process. Also, this chapter describes the application of modeling techniques for determining the influence of shrinkage and porosity during dehydration.

Milk may be concentrated as a necessary initial step in drying operation or as concentrating step in the manufacture of sweetened condensed milk or evaporated milk or the preparation of infant formulae. In order to preserve the milk constituents in a concentrated form, condensed milk/concentrated milk is manufactured from whole skim milk by removing or evaporating part of the water under vacuum. But this form of milk still has limited shelf life. Attempts to prolong the shelf life of this product have been made through the addition of bacterial growth inhibitor like sugar (sweetened condensed milk) or by heat processing (evaporated milk) to destroy the microorganisms.

Concentrated milk industry is an important segment of dairy industry. It plays an important role in the economy of industry. It serves as a balanced economy. It utilizes surplus milk in the flush season. It utilizes abundant milk production in certain localized area. It makes use of surplus milk below excellent grade. By either concentrating or drying less space is needed to store and it becomes less bulky and therefore it can be transported to any part of the world. The keeping quality of milk is increased. The concentrated products give considerable saving in the cost of packaging, storage and transportation. Milk concentrates can be easily reconstituted with required amount of water corresponding to that removed by evaporation to yield a product having normal consistency of milk. It is estimated that nearly two per cent of the world’s milk production is converted into different types of condensed or concentrated milks.

Brief history and developments: The present day concept of preservation of milk by concentration and by application of heat had the beginning with the pioneering work of French man Nicholas Appert around 1793. Gail Bordon of USA was first to commercially exploit the method of concentration of milk under vacuum. He was awarded U.S. Patent in the year 1856 for processing milk in a semi-fluid state after evaporating under vacuum. Commercial production of sweetened condensed milk by Gail Bordon started in 1856.

Concept of Entrepreneurship

Entrepreneurship can be defined as the propensity of mind to take calculated risks with confidence to achieve a pre-determined business or industrial objectives. That points out the risk-taking ability coupled with decision making. The word ‘entrepreneurship’ typically means to undertake. It owes its origin to the western societies. But even in the west, it has undergone changes from time to time. In the early 16th century, the term was used to denote army leaders. In the 18th century, it was used to denote a dealer who buys and sells goods at uncertain prices. Towards 1961, Schumpeter, used the term innovator, for an entrepreneur. Two centuries before, the concept of entrepreneurship was shady. It is only in the recent years that entrepreneurship has been recognized widely all over the world like in USA, Germany, Japan and in the developing countries like ours. Gunnar Myrdal rightly pointed out that Asian societies lack entrepreneurship not because they lack money or raw materials but because of their attitudes. Till recently, in the west, the entrepreneurship is mainly an attribute of an efficient manager. But the success achieved by entrepreneurs in developing countries demolishes the contention that entrepreneur is a rare animal and an elusive character. In India the definition of an entrepreneur being the one who undertakes to organize, own and run a business has been accepted in a National Seminar on entrepreneurship organized in Delhi in 1975. Still there has been no consensus on the definition of entrepreneurship and qualities of entrepreneurship.

a) A Key GDP Contributor: Dairy and Livestock sector form the backbone of agriculture with 28 per cent contribution in GDP and the progress in this sector is dependent on innovative measures to increase the value for farmers as well as customers.

b) Doubling Farmer’s Income : Doubling Farmer’s Income by 2022 can be achieved by improving crop and livestock productivity, efficiency to utilize resources, increased intensity of cultivation and diversification in high value cash crops, processing and value addition of food and animal products. This price realization can be assured through market reforms and efficient market linkages.

c) Unorganised sector – a challenge : The Indian dairy sector is still characterized by strong presence of unorganized sector. Apart from the Cooperative dairy sector, in the last few years there has been a considerable growth in Private Dairy sector and Milk Producers Organization like Maahi in Gujarat. If small dairy farmers are provided with sufficient ‘value addition’ training and support, they can increase their income considerably.

d) Value addition : Further, the milk processing plants can also go for value addition and innovation and in turn pay remunerative prices to milk producers.

Confectionery fills an especially direct need; the sugar of agreeableness joined with exquisite flavors, smells and mouthfeel affects a basically transitory feeling of thriving and joy. Sugar confectionery has been made all through the long haul with extending headway and it remain alive in unlimited plans following a changed levels of agreeableness, flavors just as scents, feel, appearance and tastes

Sugar confectionery and chocolate includes candies (sweets in British English), candied nuts, chocolates, chewing gum, bubble gum, pastillage, and other confections that are made primarily of sugar. In some cases, chocolate confections (confections made of chocolate) are treated as a separate category, as are sugar-free versions of sugar confections. The words candy (US and Canada), sweets (UK and Ireland), and lollies (Australia and New Zealand) are common words for the most common varieties of sugar confectionery. Confectionery depends on numerous ingredients which have been discussed in detailed in this chapter

Introduction

India’s rural economy has benefited greatly from the dairy sector. It has played a significant role in bringing about socioeconomic change. India’s dairy industry has undergone significant change as a result of the White Revolution. The “White Revolution” can be credited with increasing milk availability and providing rural India with a stable source of employment and income. The business has drastically changed to meet India’s increasing demand for milk and milk products. India is currently the world’s greatest producer of milk. The Operation Flood Program is credited with this title. The dairy market in India is projected to increase at a compound annual growth rate (CAGR) of 6.61% from 2024 to 2029, from an estimated US$26.11 billion in 2024 to US$35.96 billion by 2029 (Indus Food, 2024). With over 8 crore farmers employed and a 5% national GDP contribution, the dairy industry in India is vital to the country’s economy. With around 25% of the world’s milk supply and a massive livestock population of 536.76 million animals, it tops the world in milk production. With major markets in the United Arab Emirates, Saudi Arabia, the United States, Singapore, and Bhutan, India exports approximately 63,738.47 metric tonnes of dairy products in 2023–2024, generating US$ 272.64 million.

Abstract

Most dryers operate at low thermal efficiency. The development of models and control systems offers an opportunity to improve dryer operation and efficiency. Dryer control is very important and with deeper understanding of the drying concept, new “smart” dryers can be made more reliable and more cost-effective than classical dryers. This chapter will provide an overview of necessity of control and safety measure in food drying system, and terminology related with drying control system. Different control strategy includes conventional and advanced techniques implemented in drying operation are reviewed  here and simple outline of intelligence control system in drying technology are briefly described in succeeding section. Various hazards in drying process and risk and safety management will also be discussed.

Definition

It is one of the important portion of milk which forms a fatty layer on top of milk when left un-disturbed. It is a prime component of milk and comprises mainly of milk fat. It may be defined as “that portion of milk which is rich in milk fat” meaning portion of milk into which larger portion of milk fat has been gathered.  According to FSSAI, 2011 Malai and Cream are defined as –

Malai means the product rich in butter fat prepared by boiling and cooling cow or buffalo milk or a combination thereof. It shall contain not less than 25.0 per cent milk fat.

Butter is one of the leading milk product in developed countries of the world. It serves as a balance wheel of dairy industry. Surplus milk is generally converted into butter to be used during the times of scarcity. It is an article of commerce and a sign if wealth. Butter is a fat concentrate, which is obtained by churning cream, gathering the fat into a compact mass and then working it for proper distribution of moisture and salt. The art of butter making has a long history. The manufacture of butter was confined to colder regions where gravity creaming was successful. The milk was allowed to stand undisturbed for 10-12 hours until layer of cream collects at the top.

Chemically, sugar candies are broadly divided into two groups: crystalline candies and amorphous or non crystallized candies. Crystalline candies are not as hard as crystals of the mineral variety, but derive their name and their texture from their microscopically organized sugar structure, formed through a process of crystallization, which makes them easy to bite or cut into. Fudge, creams, and fondant are examples of crystalline candies. Amorphous candies have a disorganized crystalline structure. They usually have higher sugar concentrations, and the texture may be chewy, hard, or brittle. Hard candies, such as lollipops, caramels, nut brittles and toffees are all examples of amorphous candies, even though some of them are as hard as rocks and resemble crystals in their overall appearance. Crystalline candies are chemically described as having two phases, because the tiny, solid sugar crystals are suspended in a thick liquid solution. These are also called grained candies, because they can have a grainy texture. Amorphous candies are have only one phase, which is either solid or liquid, and do not have a grainy texture, so they may be called ungrained.

Commercially, candies are often divided into three groups, according to the amount of sugar they contain:

Introduction

Advances in food preservation methods have supported the journey of food science from that of a cookery science to a fast growing industrial technology. Food preservation knowledge deals with the way to prevent spoilage and maintenance of quality in foods. Spoilage is the deterioration in quality brought about by inherent biochemical and chemical changes, as well as microbial metabolism during food storage. Basic principles of food preservation (Frazier et al., 2008) remains the same, but newer methods for achieving the goal is added through research fuelled by a consumer demand for fresh-like foods with convenience and safety. Scientific information on novel processing methods are beautifully compiled (Cullen et al., 2011; Da-Wen Sun, 2014; Tokuþoðlu and Swanson 2015; Doona, 2018).

In-depth knowledge of physiological activities of micro-organisms in presence of preservation agents is essential for preparation of safe foods with prolonged shelf life. Besides this, it is necessary to understand the effect of food constituents on microbial resistance against inactivation agents, to identify critical dose requirement. This profound knowledge would also help to understand kinetics of microbial inactivation and to develop mathematical models suitable for a realistic design of process parameters. For better appreciation of the following sections, readers are encouraged to have fundamental knowledge in microbiology and food processing. The sections in this chapter cover advanced microbiological knowledge pertaining to the preservation aspects of food.

The world’s greatest source of cow and buffalo diversity is India, and countries like Australia, South Africa, Latin America, and the USA employ Indian cattle breeds to grow their livestock industries. The number of cattle in the nation represents 17% of all cattle in the world. 22-25% of the Indian cow population is made up of the best native milk, draught, and dual-purpose animal genetics. The majority of local cattle breeds are excellent drafters. Native livestock breeds are clearly superior in their use of subpar feed, have better heat tolerance, and greater resistance to tropical diseases.

All across the world, the dairy industry is facing numerous problems and changes. Dairy development has received a considerable boost from factors including access to technical advancements, improvements in infrastructural facilities, and the development of modern marketing insights. It is interesting to see how the dairy sector is changing globally.