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Page 1: Gourmet Foodsali

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INTRODUCTION OF GOURMET FOODS

In 1987 Gourmet Foods is a family owned partnership business started by Mr. Muhammad

 Nawaz Chattha

1st July, 2008 his sons joined him in the business

Business set up is based in Lahore

98 sales outlets in running position supported by 5 units

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MISSION STATEMENT

³Gourmet´ with an aim to make

Delicious

Hygienic

Healthy food

That contributes to positive health

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MILK PROCESSING IN

GOURMET FOODS

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COLLECTION OF RAW MILK 

Raw milk received

The farmers

Collectors from the collecting areas of the industry

Transported

Transported to the milk processing plant

Chilled at a constant temperature (40C) after being pumpedinto a storage tank for any length of time

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MILK RECEPTION

Tanker enters into the Gourmet foods, sample is taken by Labtechnician. Then Lab Technicians perform the tests needed

Then tanker  comes to the receiving area where finally the

reception of the milk takes place by the centrifugal pumps

Milk comes into storage tank then goes to clarifier 

Milk goes toward the PHE where its Chilled

and stored into the big silos

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RECEPTION LAB

The composition of milk and adulteration in milk is usuallydetermined by a number of tests on arrival at the dairy &

adulterated milk is not accepted

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STORAGE OF MILK 

After the completion of the reception tests, the tankers are

accepted or rejected if accepted then

Milk from accepted tankers receive in receiving lines

From receiving lines, milk comes in silos

There are six silos in Gourmet Foods unit 3

Capacity of 2 silos are25000 liters

Capacity of 2 silos are15000 liters

Capacity of 2 silos are 10000 liters

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TEST CARRIED OUT TO CHECK 

THE QUALITY OF MILK 

All the quality tests are carried out at the time of arrival of 

milk in the dairy plant in the reception lab.

In reception lab 4 types of tests are performed which are given  below.

Physical tests

Qualitative tests

Quantitative tests

Adulteration tests

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PHYSICAL TESTS

Taste

Check taste of milk. It should not give odd taste

Smell

Take in the aroma of milk. It should be of milky odour 

AppearanceMilk should be of uniform color and texture

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QUALITATIVE TESTS

Five qualitative tests are performed for raw milk 

1. Check temperature of milk 

2.  pH

3. Clot on boiling test (COB)

4. Alcohol precipitation test (APT)

5. Determination of Acidity

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QUANTITATIVE TESTS

In Gourmet foods Four types of quantitative tests are performed .

1. Determination of Fat in Milk 

2. Lactometer Reading (28)

3. Solids not fat (SNF )

4. Total solids (TS)

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ADULTERATION TESTS

In Gourmet foods four types of adulteration tests are performed

1. Detection of Deter gent in Milk 

2. Detection of Star ch in Milk 

3. Detection of Glucose in Milk 

4. Detection of Sugar (Sucrose) in Milk 

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PASTEURIZATION OF MILK IN

GOURMET FOODS Milk Silo

Balance tank 

Regeneration Section (44-45oC)

Separator 

Homogenizer (100-150 bar)

Heating Section (80-85oC)

Holding Tubes (15 Sec)

Regeneration Section (55-60o

C) Cooling Section (7-8oC)

Packing of milk (litter pack)

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POWDER PLANT

Milk powder is the product obtained by the removal of water 

from milk by heat

Spray dryer is used for drying and falling film evaporator is

used for the evaporation

The capacity of the powder plant is 24bags in 1 hours of 

duration consisting each bag with 25 k g of dry milk powder 

Reception and pasteurization of milk is done at unit 3 then 

send it to unit 5 for the production of powder milk 

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MANUFACTURING OF POWDER MILK IN

GOURMET FOODS

Milk silo

Balance tank 

Standardization Pasteurization

Storage of milk into tanker 

Milk from unit 3 transfer to unit 5

Evaporation (Brix 40-50)

Spray dryer (remove water)

Packing into bags

Storage cold & dry place

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GHEE

It is desiccated butter 

Which have moisture content not more then 0.5 %

Shelf life is up to one year 

Gourmet Foods produce its own desi ghee for the purpose of 

making sweets

Gourmet desi ghee is not for sale

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GOURMET DAIRY

ICE CREAM

It is frozen product which is obtained by the blending of fat,

SNF, sugar, stabilizer, emulsifier incorporated with air when 

we freeze

In Gourmet foods two kinds of mixes are produce for ice

cream manufacturing Kulfa mix and plain mix.

In Gourmet Foods 15 kinds of ice cream are manufacture

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RAW MATERIAL FOR ICE CREAM

1. Sugar 

2. Dry Skim Milk 

3. Fresh Cream

4. Liquid Glucose

5. Pulsgaurd

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ICE CREAM MANUFACTURE

The basic steps in the manufacturing of ice cream are generally asfollows

Blending of the mix ingredients Pasteurization (80-85oC)

Homogenization (100-150 bars)

PHE (8oC)

Aging the mix (4-6 hours)

Freezing 

Packaging 

Hardening (-30 to -35oC for 24 hours)

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KHOYA

Khoya is concentrated whole milk product having moisture

 per centage 35%

In Gourmet foods Khoya contain 35-40% fat

After the manufacturing of khoya, it is packed

Khoya is also not for sales

Khoya is used for the preparation of sweets

Some time khoya is used in the preparation of kulfa ice cream

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PREPARATION OF KHOYA

In Gourmet food stainless container with steam jacketed are used

for the preparation of Khoya

Take raw milk at 10-12oC in to pan

Heat milk at 85-90oC for 30 minutes and stir 

Then addition of milk powder 3k g+3liter water at 65oC

Then cooling at room temperature

Then pack Khoya into 10k g polyethylene bag

Shelf life is 5-8days at room temperature

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PANEER 

Paneer is a product obtained by heating and acid coagulation of 

milk 

It should not contain moisture above then 70% and fat contain 

23-26 %

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PREPARATION OF PANEER 

Raw Milk is come into paneer section temperature of milk is4oC

Then boil the milk for 1-2 minutes at 95oC and continuously

agitate the milk 

Then cool the milk up to 70oC and continuously agitate the milk 

Citric acid is added in milk and curd is formed with in 5-6minutes

Ageing is done for 8-10 minutes with slow agitation

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Whey is drained off 

Washing of  curd with water and whey+water is removed

At this stage curd has not sour taste

Separation of curd by the help of cheese clothes by pressing 

the curd

Mining of paneer is done

Then pack and store at 4oC

Paneer is used for the manufacturing of sweets

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CLEANING IN PLACE

Before any operation during milk processing anything must be

clean

Cleaning is carried out by cir culating of cleaning agent in 

 processing line is called C.I.P

In Gourmet foods C.I.P carried out by following steps

1. Water rinsing for 10 minutes

2.  NaoH rinsing for 10 minutes3. Water rinsing for 5 minutes

4.  Nitric acid rinsing for 10 minutes

5. Water rinsing for 5 minutes

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WATER SOFTENING PLANT

In Gourmet foods 2 water softening plants are present

Capacity of both plants are 4 tons

Water softening by Na-zeolite

Zeolite react with Ca+2, Mg+2 ions and convert into Ca, Mg 

Zeolite

Limit of hardness is 60 ppm

Zeolite should be changed after every year 

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BOILER 

In Gourmet foods 2 boiler are used for production of steam

It is also called steam generator 

The temperature of steam is 180oC

Boiler #1 Boiler #2

Types Fire tube Fire tube

Capacity 4 tons/hour 6tons/hour 

Working pressu

re 250PSI 150PSITDS 3000-4000ppm 3000-4000ppm

Company PIE PIE

Modal PIE1011 PIE1016

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Feed water pressure is 10-15 PSI high to boiler pressure

Boiler efficiency depends upon feed water temperature

To increase the temperature of feed water economizer is used

Economizer is placed at the exhaust side of boiler 

Economizer increased the boiler efficiency 2-10 %

Gas and fur nace oil is used to operate the boiler 

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COMPRESSOR 

Gourmet foods three types of compressors are used

1. Ammonia compressor 2. Freon compressor 

3. Air compressor 

Power rang of compressors are 3-30 hp Hermetic type

 Not repairable

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CONDENSER 

Gourmet foods 2 types of condensers are used

1. Air cooled2. Shell and tube

Condensers are local & German made

Hermetic type  Not repairable

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FREEZER 

In Gourmet foods 12 freezers are used

4 freezers are Italy made and 8 freezers are china made

Power range of freezers are 10-15hp

Two types of freezers are used in Gourmet foods

Air blast freezer (storage)

Continuous freezer (ice cream)

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COOLING TOWERS

Gourmet foods 4 cooling towers are used

They are natural type

Capacity of each cooling tower is 150 tons/hour 

When water enter in cooling tower temperature is 35oC

When water leaves cooling tower temperature is 27oC

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GENERATOR 

Gourmet foods 2 generator are used for the production of electricity in cause of emer gency

Generator # 1 Generator # 2

Model P730P 800F

Color Blue Yellow

Made Ireland U.K  Ireland U.K 

Power 730KVA 725KVA

Company FG Wilson CAT

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