Producing Amul Milk Powder involves a precise industrial process to remove water from milk while preserving nutrients, flavor, and shelf life. Here’s a detailed step-by-step breakdown:
1. Raw Material Sourcing & Quality Check
- Source: Fresh cow/buffalo milk from Amul’s cooperative network.
- Quality Tests:
- Fat content (adjusted for skimmed/full-cream powder).
- Acidity, density, and microbiological safety (no pathogens).
- Antibiotic/residue screening (as per FSSAI standards).
2. Standardization
- Milk is separated into cream and skim milk via centrifugation.
- Fat adjustment:
- Full-cream powder (FCP): 26–28% fat.
- Skimmed milk powder (SMP): <1.5% fat.
- Cream is added back to achieve desired fat levels.
3. Heat Treatment (Pasteurization)
- Milk is heated to 72°C for 15 seconds to kill bacteria, yeasts, and molds.
- Followed by immediate cooling to 4°C to prevent spoilage.
4. Pre-concentration (Evaporation)
- Milk is concentrated in multi-stage vacuum evaporators at low temperatures (45–60°C).
- Goal: Remove ~85% water to achieve 40–50% total solids.
- Benefits: Reduces energy needed for drying and improves powder solubility.
5. Homogenization
- Concentrated milk is forced through tiny nozzles under high pressure.
- Purpose: Breaks fat globules for uniform texture and stability.
6. Spray Drying
- Key step: Convert liquid concentrate into powder.
- Process:
- Concentrate is sprayed as fine droplets into a drying chamber (180–220°C hot air).
- Water evaporates instantly, leaving hollow powder particles.
- Powder falls to the chamber base; air is cycled out.
- Equipment: Industrial spray dryers with centrifugal atomizers.
7. Fluidized Bed Drying (Secondary Drying)
- Powder moves to a vibrating fluidized bed dryer.
- Goal: Remove residual moisture (3–4% final moisture content).
- Cooling: Powder is cooled to 25–30°C to prevent caking.
8. Sifting & Agglomeration
- Sifting: Removes lumps for uniform particle size.
- Agglomeration (optional):
- Fine particles are steam-treated to form larger granules.
- Advantage: Improves solubility (e.g., for Amul’s “Insta” range).
9. Packaging
- Powder is packed in multi-layered bags (food-grade polyethylene + aluminum foil):
- Blocks moisture, oxygen, and light.
- Nitrogen-flushed to prevent oxidation.
- Sizes: Bulk (25 kg) for commercial use; retail packs (100g–1kg).
10. Quality Control & Testing
- Critical checks:
- Moisture content (≤4%).
- Solubility index (≥85%).
- Microbiological safety (total plate count <10,000/g).
- No contaminants (aflatoxins, heavy metals).
- Shelf life: 18–24 months (unopened).
Key Technologies Used by Amul
- Milk Analyzers: Near-infrared (NIR) sensors for real-time composition checks.
- Automated Control Systems: Precision monitoring of temperature, pressure, and flow.
- Traceability: Batch coding for recalls.
Types of Amul Milk Powder
- Amul Full Cream Powder: 28% fat, creamy flavor.
- Amul Skimmed Milk Powder: <1.5% fat, high protein.
- Amul Instant Milk Powder: Agglomerated for quick dissolution.
Challenges & Solutions
| Challenge | Solution |
|---|---|
| Nutrient loss during drying | Low-temperature evaporation |
| Powder caking | Moisture control + anti-caking agents |
| Fat oxidation | Nitrogen-flushed packaging |
Regulatory Compliance
- FSSAI (India): Adherence to Food Safety Standards (Milk Products) Regulations.
- International: HACCP, ISO 22000 certification for exports.
Did You Know?
- 1 kg of milk powder requires 8–10 liters of milk.
- Amul produces powder at Anand (Gujarat) and other mega-dairies.
This industrial-scale process ensures Amul milk powder retains nutritional value, safety, and taste. For home use, simply reconstitute powder with water (1:4 ratio for milk). 🥛
