MODEL DAIRY PLANT

N.D.R.I., KARNAL.

A state-of-the-art commercial Dairy Plant has been

established in the year 1996 at NDRI, Karnal installed on
turnkey basis by the National Dairy Development Board.
The Plant has been designed to handle 60,000 liters of milk
per day and is presently running in full capacity.

SPECIAL FEATURES:

Model Dairy Plant is providing In-plant Training to the students of B.Tech (DT) of the N.D.R.I. Deemed
University in their 3rd year of the 4-year course curriculum.

The students are provided with complete infrastructure for training, which help them in gaining the
experience in managing a modern commercial Dairy Plant and instill confidence in handling real life
problems in production management.

It is also providing infrastructure facilities to the scientists of NDRI for scaling up R & D concepts from
the laboratory to the industrial scale under the commercial environment.
Model Dairy Plant (MDP), an autonomous unit of ICAR, is independently managed by duly constituted
Committee, whose Chairman is the Director of NDRI. The other Committee Members are 1) Representative
of NDDB, 2) ADG, ICAR, New Delhi, 3) Managing Director, Mother Dairy Food Processing Ltd., Delhi, The
General Manager (MDP) is the convener. The Head, Dairy Technology Division, NDRI has been identified as
the Coordinator in matters related to Model Dairy Plant.
LIQUID MILK PROCESSING/PACKAGING (CAPACITY 60000 LPD)
MDP has the capacity for processing and packaging 60,000 MODEL DAIRY PLANT, KARNAL

liters of milk per day (LPD). MDP is currently engaged in 70000

processing and packaging of milk for Mother Dairy on Job- 60000

work basis for five different variants (Full cream, Standard, 50000
QTY IN LTS.

Toned, Double Toned & Skim Milk). MDP is presently 40000

30000
processing & packing approximately 60,000 liters of poly 20000

packed milk for the Mother Dairy Marketing outlets in 10000

Delhi. The Plant is running in three shifts and the milk 0

96-97 97-98 98-99 99-00 00-01 2001-02 2002-03 2003-04 2004-05 2005-2006

supplies from MDP are dispatched in the evening and Sale 3000 14200 41400 43700 43600 40800 41000 49500 42770 58869

morning to the Delhi market thereby utilizing the plant to its AV. DAILY MILK SALE

full capacity.
ICE-CREAM MANUFACTURE (CAPACITY 12000 LPD)
MDP on the monthly average is processing/packing Ice MODEL DAIRY PLANT, KARNAL

cream approximately 7500 liters per day (LPD) for the 1500

Mother Dairy also in job-work thereby utilizing the full 1200

capacity of the unit. The production of Ice cream is

QTY. IN 000' LTS.

900

further enhanced to 12000 LPD during the summer 600

season. The Ice-cream manufactured at MDP is of 300

different varieties like Vanilla, Strawberry, Shahi Malai, 0

Kewra, Thandai, Butter Scotch; etc is as per the Series1

2000-01

312
2001-02

708
2002-03

1054
2003-04

1121
2004-05

889
2005-06

1435

requirements of Mother Dairy. ICE CREAM PRODUCTION / SALE

MDP is also supplying Ice cream in its brand name through the Milk Parlour of NDRI in 100 ml cups and one
liter bricks. The product has been well accepted and response is quite satisfactory and encouraging.
GHEE MANUFACTURING (CAPACITY 800 KG PER DAY)
MDP manufactures Ghee from the surplus fat 100
MODEL DAIRY PLANT, KARNAL

available from the standardization of milk and its 80

production is not taken as per demand. The average

QTY. IN 000' KGS.

60

production/sale of ghee is 7-8 metric tons per month 40

which is sold through the NDRI milk parlour and local 20

distributor appointed by MDP. 0 96-97 97-98 98-99 99-2000 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06

SA LE 10.00 16.00 64.00 89.00 63.00 65.00 97.00 96.00 42.00 59.00

GHEE SALES (M.Tons)

PROCUREMENT OF MILK
MDP does not have its own infrastructure for milk procurement. It is receiving milk on behalf of Mother
Dairy from the units of Punjab / Rajasthan / Uttar Pradesh State Federations at NMG rates. The average milk
procurement per day is around 50,000 to 55,000 LPD, which is sufficient to meet the daily demand of
different milk variants being packed at MDP.
TRAINING TO THE STUDENTS
As the primary objective, Model Dairy Plant provides In Plant training to the B.Tech. (DT) students of NDRI
(Deemed University). The students are provided with an In-plant training manual comprising of unit wise
operation covering all the section of Dairy plant. Since its inception, MDP has provided training to the ten
batches of B.Tech (DT) students. The student trainees are provided with Rs.1500 per month as stipend. MDP
has spent Rs.33.00 lakhs till date on account of stipend paid to the students who have undergone training at
MDP.
Students are given hands on experience for plant operations and trained to manage the shift activities of the
plant under the guidance of trained technical staff.
In Plant training of NDRI students at Model Dairy Plant
B.Tech (D.T.) III Yr Ph. D (D.T.)
YEAR Nos. / Period Nos. / Period
2002-03 15 (01.08.02-31.07.03) 3 (17.06.02-31.07.02)
2003-04 24 (01.08.03-31.07.04) 3 (16.06.03-15.10.03)
2004-05 23 (01.08.04-31.07.05) 4 (01.07.04-31.10.04)
2005-06 26 (01.08.05-31.07.06) NIL
In addition, the students are also involved in other activities like Kaizen’s (individual improvement activities),
Small Group Activities etc. The feedback regarding Inplant Training, from the student’s trained at MDP and
now working in different capacities with different organizations is quite positive and encouraging.

QUALITY MANAGEMENT SYSTEM.

Model Dairy Plant has been implementing the Quality Management System / HACCP principles since
September 2000 and is certified under the Quality System IS/ISO 9001:2000 and Food Safety (IS
15000:1998) HACCP.
HRD PROGRAMMES KAIZENS & SGAs
Model Dairy Plant has well trained technical staff MDP has started Advisory Activities (KAIZENs)
to handle the various operations of the plant. For and Small Group Activities (SGA) for its
further upgrading the knowledge and skills of the continued improvements by involving the
employee, MDP is continuously taking up HRD employees, students and the floor level staff. The
programs through external agencies for up concept has been well implemented and the
gradation of knowledge and motivation of the employees, students and the workforce engaged at
employees and student trainees, which has been MDP, have made several improvements, by which
quite beneficial and helpful both to the employee the organization has benefited.
and the organization.
VISIT BY DIGNITARIES
Model Dairy Plant is a place regularly visited by national and international dignitaries. Faculty members
and students of different institutions also visit the plant. Visitors and dignitaries, who have so far visited
MDP, have appreciated the quality of work vis-à-vis hygiene and quality training being imparted to the
students of Deemed University NDRI.
AWARDS AND RECOGNITION
The continuous improvements in the system have made MDP an award winning organization. MDP was
awarded the National Productivity Award for Best Productivity Performance in Dairy Development &
Production (2004-2005). The award was presented by Sh. Sharad Pawar, H’able Union Minister of
Agriculture, Govt. of India in a glittering function held at Scope Complex, New Delhi on May 10, 2005
jointly to the Chairman, MDP, Dr. Sushil Kumar and General Manager MDP, Sh. B.B.Raina.