ABSOLUTE IS PURE HAPPINESS
Setting
Our plant is located in a large expanse of 11 acres in Muchintala village near Hyderabad airport. It is in our farm. Buzzing with activity, every day something new is coming up here! The proximity of the plant to the cattle and the fields where we grow our indigenous feed, is basically to ensure that all the elements that contribute to the making of the products are in our eye view and we get them all from a single source, controlled and supervised and made to order in a manner of speaking. Our first plant was 1000l/hr capacity concentrated on by products such as paneer, matka dahi and ghee. The first ever order we received was for 5 kgs of paneer! From there the second phase 3000 l/hr. Then came the Yadagirigutta blessing. We added the ghee plant for making vedic ghee/modern ghee and matka dahi. 1.5t/4hrs.In 21-22 began the next phase. We added 5kl/hr complete curds plant targeting 1 lakh litres per day. We are the only dairy plant that has a cold storage for 150 T of butter at -20°C and 50T at +2°C.
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ABSOLUTE IS PURE HAPPINESS
Green Ideas
Right from the word go we wanted a green plant and we worked towards that. Our planning was for a judicious 3 months before we hit the ground.One of the green features is our Glycol plant. It replaces the traditional ammonia plant by providing instant cooling rather than running an ammonia plant continuously. In 15 min we are able to achieve the needed temperature, saving on power consumption. Simple ideas like bifurcation of the electric control panels so the electricity consumption is optimised and directed properly and in a timely manner to the core, auxiliary and ancillary areas helps in power savings.Our Boiler is yet another engineering idea. It has been designed in such a way that we calculated the steam needed for the instrumentation. We direct the needed steam to the specific facilities. The boiler is designed to preheat the water by using the flue gases to 65-7-0°C. Then moving the temperature upto 110°C becomes easy and is power saving. Our Clean In Place system (CIP) is the core to the plant hygiene standards. With multiple pipelines we are able to handle the cleaning process on as is when needed basis, and do it as many times as needed. We don’t have to wait for the shift to get over. We have a 5KL plant to clean the machinery.
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ABSOLUTE IS PURE HAPPINESS
Details
We are the first in South India to have an automated 5 Kl/hr plant. Our plant can be run by one operator. Another of the unique details at our plant are our Deaerators. Standing tall like one of India’s leading brands – Amul, we also have Deaerators. Two Deaerators work at the Raw Milk Reception Dock (RMRD) to remove the farm/ cattle smell from the milk. These help in removing unwanted odours at both the raw material and product level. Deaerators play a significant role in the making of curds. Our paneer is made
using a pneumatic press which has been programmed to create cycles of compresses- expands- compresses so that the surface area is fully covered and the weight/pressure is evenly distributed while preparing the paneer.This ensures that the paneer is practically free of water. So, when you pay for our paneer you pay for the full protein, not for the water unlike others.Gram to gram you are paying for the paneer. Our milk processing machinery is from Tetrapak, Sweden.
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ABSOLUTE IS PURE HAPPINESS
Traceability and checks
Traceability is a well planned method for us. Here is how it works: we select a set of buffaloes/cows. We assign one, numbered can to the milking personnel. A particular timing of milking is given. Instructions that each animal will not be milked for more than 6 minutes are given. Each animal is assessed – lactation assessment is done on a regular basis. Our experience tells us that we may get 4 litres in every sitting. 1.5 litres to the calf and the balance 2.5 litres for commercial use. Once the milking is done the milk is collected and passed through filtering and sieving systems and not poured into a dump tank. The central idea here being traceability, so that we can identify by can and the personnel. Each and every can is sampled for testing. Fat content, microbes /bacteria and SNF (solid non fats), water , temperature of the milk to detect a fatigued or sick cattle. In addition to this the cattle are observed carefully. Following strict methodologies the milk is processed. The plant is kept clean, hot water sanitisation is done on a regular basis. Incubation rooms undergo iodine cleansing at periodic intervals. The water that flows as waste after the cleansing process is treated for effluents and directly discharged into the greenery around the plant.
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