Lassi Manufacturing Process in Plant

Lassi Manufacturing

Purpose: To manufacture and pack Lassi as per the specifications
Scope: Respective product section
Responsibility: Production and Quality Assurance department
1. Ingredients:
1.1 Dahi made from Standardized Milk: The milk shall be standardized, pasteurized & shall meet the specifications (As per PS-QA-13).
1.2 DVS culture: As recommended
1.3 Pasteurized Soft water (hardness < 10 ppm)
1.4 Sugar As per IS 1151:2003
1.5 Spiced powder – Spiced Lassi Seasoning 160410 P / 021210P
1.6 Edible common salt – As per IS 253:1985
2. Equipment & Utilities Required
2.1 Storage tank / silo
2.2 Multi-purpose storage tank / vat
2.3 PHE (With holding time / Temp.10 minutes / 90°C)
2.4 Milk chiller
2.5 Pouch packing machine
2.6 Lassi thermizer (pasteurizer)
2.7 Shear Pump
2.8 Cold storage to maintain less than 4°C
2.9 Pumps ,valves & pipe lines
2.10 Crate washer
2.11 Crate conveyor
2.12 Chilled water (0 to 1ºC).
2.13 Electricity (415 V 3-phase & 230 V single phase)
2.14 Voltage stabilizer
2.15 Soft water (hardness < 10 ppm)
2.16 Steam (2 to 3 Kg / cm )
2.17 C.I.P system
2.18 Compressed air (6 Kg / cm )
3. Packaging Requirements:-
3.1 Primary packing: Poly film
3.2 Secondary Packing: Crates
4. Procedure:
4.1 Refer procedure (4.1 to 4.11) for dahi manufacturing.
4.2 The temperature and acidity development of the milk shall be monitored periodically till dahi is formed in the tank / vat with acidity level reached 0.85 ± 0.05%.
4.3 15% (of dahi) pasteurized chilled water should be added in the tank / vat to break the dahi with agitator .It should be circulated through shear pump. Product should be cooled inside the tank / vat by circulating chilled water in the jacket of the vat / tank.
4.4 Further addition of pasteurized chilled water (85% of dahi for plain lassi, 157% of dahi for low fat lassi,156% of dahi for spiced lassi,147% of dahi for sweet lassi including water used for sugar syrup preparation).
4.5 In case of spiced lassi; addition of spice powder and edible common salt @ 0.5-0.7% & 0.45% of lassi respectively and in case of sweet lassi addition of sugar @ 10% of lassi (sugar to be dissolved in hot water at 70 ºC and filtered).
4.6 Product should be tested for chemical & sensorial properties by QA.
4.7 The product should be thermized at 65± 2° & filled with packing machine at 3 ˚C.
4.8 During the packing ,the production staff will check the weight, length, coding and sealing of pouch at regular interval and will be counter checked and certified by the QA.
4.9 The C.I.P of filling machine should be done after every 8 hours along with pipe lines.
4.10 Before stacking the pouches in the crates, supervisor / in-charge will ensure that crates are
properly cleaned (inside and outside).
4.11 Hygienic conditions of equipment and filling area should be maintained.
4.12 Filled crates should be stacked up to 10 crates in the cold store and temperature of the cold store should be maintained at < 4 C.
4.13 The packed lassi should be dispatched at below 5 C.
4.14 Guidelines of GMP (as per IS 16021:2012) should always be applied during manufacturing, packing and dispatch.
5. Clearance Procedure:-
5.1 Raw materials :The pasteurized milk (As per PS-QA-13) and Dahi quality shall be checked and certified by QA Section.
5.2 Final product :The final product shall be sampled and tested for each lot to ascertain that the
product should meet the product specification (As per PS-QA-14).
5.3 The final product shall be dispatched to market only after verifying its quality by QA section
6. 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.
7. Shelf life: Shelf life should be declared minimum 5 days from the date of packing when stored
under refrigeration below 5 C