Paneer Manufacturing Process in Plant

Paneer Manufacturing

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


2. Ingredients Specifications:
2.1 Pasteurized standardized Milk:
a) Fat 5.00% ± 0.05% & SNF 8.60% ± 0.05%
b) MBRT Min. 6.00 hrs
c) Phosphatase test: Negative
d) Acidity (L.A) 0.13% ± 0.01%
2.2 Citric Acid as per IS 13186:1991
3. Equipment & Utilities Required
3.1 Milk Storage Tank
3.2 PHE for milk with holding at 90˚C for10 minutes and milk outlet temperature at 74 ± 2ºC
3.3 Paneer Hoops
3.4 Paneer Press
3.5 Paneer cooling Vat
3.6 Paneer cutting machine
3.7 Paneer shredding machine
3.8 Paneer pouch sealing machine
3.9 Cold Store (less than 4°C)
3.10 Steam (2-3 Kg / cm )
3.11 Chilled water (0-1 C)
3.12 Compressed air (6 Kg / cm )
3.13 Soft water (hardness < 10 ppm)
3.15 C.I.P system
3.15 Electricity (415 V 3-phase & 230V single phase)
4 Packaging Requirements:
4.1 Primary packing :Paneer Pouch
4.2 Secondary Packing :Crates and poly-pack
5. Procedure:
5.1 The quality of the pasteurized standardized milk, citric acid shall be tested by QA.
5.2 Controls and measuring instruments should be calibrated in fixed interval.
5.3 All the CCP should be strictly maintained by production department and certified by the quality assurance fortnightly.
5.4 Weighing scale should be calibrated with the standard weights in every shift by the operator and will be certified by the supervisor / in-charge.
5.5 Hygienic conditions of equipment and filling area should be maintained.
5.6 Operator will check all operational parameters and working of the machine as per the checklist displayed and supervisor / in-charge will certify.
5.7 Complete pipe line, balance tank, PHE, coagulation vat, pressing machine, hoops and cooling vat should be properly cleaned and sanitized before starting and after completion of operations .Quality assurance staff will certify its cleanliness before its use.
5.8 Pasteurized milk should be heated at 90º C for at 10 minutes with outlet temperature 74 ± 2ºC.
5.9 Citric acid @ 0.18% of milk in water (strength of citric acid solution should be 1%) at 74 ± 2ºC should be added. This should be done slowly with gentle agitation till milk coagulates completely.
5.10 The coagulum should be hold for 5 minutes and then the whey should be drained out.
5.11 The coagulum should be poured in clean / sanitized muslin cloth and should be hooped in paneer hoops.
5.12 These hoops should be then subjected to pressing at 6 kg / cm for 10 to 12 minutes.
5.13 The paneer block should be removed from the hoops and to be kept in vat containing pasteurized
chilled water (Temperature max. 10ºC) for 90 to 120 minutes after cutting in proper size .The water temperature shall be maintained to below 10ºC.
5.14 The paneer should be packed at < 15 ºC. The extra shredding of the paneer should be collected and to be kept in hot water (80 to 90 ºC) before adding to milk for coagulation.
5.15 The packed product should be immediately kept in cold-store maintained at < 4 ºC.
5.16 The samples should be tested to confirm the final composition by QA. The final product shall also be tested by QA for its body, texture and organoleptic test before dispatch.
5.17 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 standardized milk and citric acid quality shall be checked and certified by QA.
6.2 Final product: The final product shall be sampled and tested for each lot to ascertain the product meeting the specifications.
6.3 The final product shall 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: Minimum 5 days from the date of packing when stored under refrigeration below 5 C