Kheer Manufacturing Process in plant

Kheer Manufacturing

Purpose: To manufacture and pack Kheer
Scope: Respective product section
Responsibility: Production and Quality Assurance department





2. Ingredients:
2.1 Pasteurized Standardized Milk which shall meet the following specifications:
a) Fat 3.0% ± 0.05 %,
b) SNF 10.0% ± 0.05 %
c) MBRT: Min 6.00 hrs.
d) Phosphatase test :Negative
e) Acidity % (L.A) max.0.145
2.2 Rice – Basmati half piece of reputed brand (6 months to 12 months old). It should be free from extraneous matter.
2.3 Sugar– As per IS 1151:2003
2.4 Green Cardamom :As per IS 1877:1985
2.5 Sodium Benzoate- (IP grade / IS 4447:1994)
3. Equipment & Utilities Required
3.1 Milk storage tank
3.2 Kettle with surface scrapper
3.3 Double jacket hopper with facility of cooling and stirring
3.4 Kheer filling and sealing machine
3.5 Cold-store
3.6 Steam (2-3 Kg / cm )
3.7 Tap water
3.8 Chilled water (0 - 1 C)
3.9 Compressed air (6 Kg / cm )
3.10 Electricity (415 V 3-phase & 230V single phase)
4. Packaging Requirements:
4.1 Primary packing :Cups, Aluminum lids for cups
4.2 Secondary Packing :Corrugated boxes
5 Procedure:
5.1 The quality of the pasteurized standardized milk shall be tested by QA for its sensory, chemical and microbiological test.
5.2 Kheer kettle, hopper and cup filling machine should be properly cleaned and sanitized before starting and after completion of operation. Quality assurance staff will certify its cleanliness before its use.
5.3 Operator will check all operational parameters and working of the machine as per the checklist displayed and supervisor / in-charge will certify.
5.4 Controls and measuring instruments should be calibrated in fixed interval. 5.5 All the CCP should be strictly maintained by production department and certified by the quality assurance fortnightly.
5.6 Pasteurized milk should be taken in Kettle and boiled for about 10 minutes with continuous stirring and scrapping.
5.7 Rice will be sorted and washed prior to addition.
5.8 After 10 minutes of first boiling, rice should be added in the kettle and boiling, stirring and scrapping should be continued.
5.9 Sugar @ 8% of milk should be dissolved in hot milk (about 20 kg) and then filtered. The cardamom powder and Sodium Benzoate should be added in sugar solution.
5.10 Sugar solution in milk with ground cardamom and sodium benzoate should be added when the concentration reaches to 15 to 16% TSS when measured with refractometer and boiling should be continued with stirring and scrapping.
5.11 Product should be tested for sensorial properties by QA before the product is transferred to double jacketed hopper with cooling facility to cool the product to 70±2ºC when the final concentration reaches to 24 to 25% TSS and the weight of the product is around 85 ± 1 kg.
5.12 Weighing scale should be calibrated with the standard weights in every shift by the operator and will be certified by the supervisor / in-charge
5.13 Hygienic conditions of equipment and filling area should be maintained.
5.14 During the packing ,the production staff will check the weight ,coding and sealing of cup at regular interval which will be counter checked and certified by the QA.
5.15 The product should be filled in cleaned cups, sealed by packing machine and kept in crates for further cooling in the cold-store at temperature < 4ºC.
5.16 The samples should be tested to confirm the final composition by QA.
5.17 The product should be packed in CBX when product temperature reaches to below 5 C. The final product shall also be tested by QA for its body ,texture and organoleptic test before dispatch.
5.18 Guidelines of GMP (as per IS 16021:2012) should always be applied during manufacturing ,packing and dispatch.
6 Clearance Procedure:-
6.1 Raw Materials :The pasteurized milk, rice ,sugar, green cardamom and sodium benzoate quality shall be checked and certified by QA and production section.
6.2 Final product :The final product shall be tested for each lot to ascertain the product meeting the specification of the product.
6.3 The final product should be dispatched for market only after verifying its quality by QA Section.
7 Transportation requirement: Product shall be transported in insulated / refrigerated vans
depending upon the distance. Before loading it should be assured by the marketing section that
vehicle is properly cleaned (inside and outside) and certified by the QA section.
8 Shelf Life: Shelf life should be declared minimum 10 days from the date of packing when stored under refrigeration below 5 C