Professional Documents
Culture Documents
This project is focusing on setting up an on farm value addition chain to enhance productivity from the daily
milk produced. The Project will use the produced milk to make Yoghurt, Ice Cream and Pasteurized Milk
Contents
Introduction and market overview
Section 2 - Yogurt
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14
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This information is intended as a guide only. Please seek detailed support from your accountant, bank, legal advisor or other specialist support organisations.
Telesat International has developed a comprehensive guide detailing information on where to source products, training and knowledge for Innovation.
Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667
There has been significant growth in the areas of luxury and indulgent products. It is unlikely any farm-based
diversification project will be able to compete in the lower end of the market; the major opportunity lies with the added
value, luxury products, with the opportunity to exploit provenance as part of the brand positioning.
It is not easy to acquire certified statistics about Uganda liquid milk market share distribution but on the face of it, we
can see that the market is generally getting split with the increasingly growing demand for value added products such as
semi skimmed, whole milk and skimmed milk. In urban areas, doorstep sales continue to decline unless being
specifically developed as more of a service.
World over, branded milks are still a large opportunity but must have a genuine unique selling point (USP) and not just a
label. Added value specialty milks such as milk enriched with Omega 3 remain a significant opportunity and growth
sector.
Yogurt / Ice Cream and Pasteurized milk processing use similar equipment and have in general terms less technological
demands and provide faster cash turn around with significantly less working capital requirements than cheese. For this
reason these products have been grouped together.
This briefing aims to provide a realistic guide to minimizing some of the risks involved in investing in Yogurt, Ice Cream
and Milk processing. It sets out some of the steps needed to ensure production of the right product, at the right quality
and marketed to the right people.
The yogurt and pot dessert markets are considered a strong category and one in which consumers demand choice,
quality and innovation. Sales have been boosted bringing innovation and new entrants together with significant
marketing spend by the major manufacturers of branded produce with year on year growth.
The ice cream market can be clearly divided into the commodity value sector and the premium, added value sector
dominated by some brands such as Fido Dido.
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Some of the key HACCP areas to be considered are given below. This is not meant to be a comprehensive HACCP
description for the manufacture of dairy products, but a general overview.
Purpose
The purpose of a HACCP system is to ensure the production of safe food. Potential hazards to food safety relating to all
aspects of the manufacturing process are identified as Critical Control Points (CCPs), and suitable records must be produced
to prove that they are controlled.
Some benefits of HACCP
Preventative system
Systematic approach
Assists due diligence defence
Facilitates verification activities
Demonstrates management commitment
The HACCP system
The first task is to address the HACCP pre-requisites, and these are:
The next task is to identify the process / product hazards, and document the CCPs on a process flow diagram.
Hazard analysis overview
Good personal hygiene
Correct cleaning and disinfection
Adequate pest control
Trained and aware operatives
Section 2 - Yogurt
2.1 Summary of business plan for Yogurt Imaginary Case Study
We assume that, we have an on farm operation that keeps about 100 cows, producing around 3000 litres of milk
per day.
From the milk produced, we can establish a clotted cream business but since this will leave us with a lot of
skimmed milk, we shall put up a Yoghurt production line.
The Yoghurt production facility can be set to work for three to four days per week with a maximum capacity of 100
litres per batch. The number of batches produced per day will depend on the market size and demand.
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provides a clean medium for culture growth and also improves consistency by denaturing the whey proteins.
2.2.7 Culture addition
A culture of harmless micro-organisms, which converts the milk sugar, lactose, into lactic acid, is added to the mixture
and stirred. The yogurt can be filled at this stage and incubated in the pot if set yogurt is required.
2.2.8 Incubation
The yogurt mixture is incubated until the required acidity has been reached. Incubation temperatures and acidities may
vary depending on cultures used and final product requirement.
2.2.9 Cooling and flavour addition
The incubated yogurt mixture is cooled to ~ 12 - 15C to retard any further increase in acidity. Colours, flavours, fruit
etc. are added and mixed as required by the recipe.
2.2.10 Filling
The finished yogurt is filled into pots and lids and labels applied.
2.2.11 Storage / testing
The finished product is transferred to a cold store and cooled to below 4C ready for despatch and sale. Product testing
for compliance with legal requirements is carried out at this stage.
Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667
Ingredients Addition:
Manufacturing Tank
Milk
Skimmed milk powder
Sugar
Stabilizers & Emulsifiers
High Shear Mixing
Homogenization
Cooling (350C)
Culture Addition
Incubation
Cooling (~10 150C)
Storage/ Testing
Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667
..
Item
Daily Production Costs:
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Running Costs
Used Equip
ce)
Using new equipment
NNew Equip
Processing
Labour
Ingredients
Equipment
Buildings
Daily admin and other running costs
Admin and maintenance
Product delivery
Building repairs
Return on capital
Return on working capital
Product storage
Sub total excluding packaging
Sub total to produce 1 litre
Sub total to produce 500ml
Packaging cost per 500ml
Total cost before profit
Profits at 20%
Ex-farm cost per 500ml
Note 1: Capital costs for equipment (new and second-hand) will depend on availability.
Note 2: The prevailing milk price in this illustration is put at
Note 3: The costs for other packaging sizes can be evaluated by adding the cost of packing with the processed
product.
For example, cost of processed product for 200ml is from the above table. The cost of plastic container and
foil lid would be about .. Therefore, the total cost before profit would be ..
Note 4: No two enterprises will be able to cost products similarly. Producers will need to carry out their own
detailed costing.
Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667
PersonalLockers
Areatoremove
outsideclothing
andfootwear.
Sitonbench
swinglegsover
andputdairy
protective
clothingand
footwearon.
ProtectiveClothing
Drain
Wash
Sink
ChilledWaterUnit
Drain
Drainer
Drain
IncubationTank
(Optional)
Hand
WashSink
Drain
Drainer
AirCompressor
Pasteuriser
(Batch)
Drain
Rinse
Sink
Hose
Hose
Drain
IncubationTank
(Optional)
Drain
YogurtAdditionsArea
Drainer
PackagingStore
PleaseNote:NottoScale
AlwaysconsulttheLocalEnvironmentalHealthOfficer(EHO)andPlanningandBuildingRegulationsdepartmentsatallstages.
Boiler
MixTank
Shear
Hand
WashSink
RawMaterialStore(Ingredients)
Homogoniser
ChemicalStore
Toilet(withhandwashsink)
StepOverBench
Hand
WashSink
CoveredUnloadingArea
Fig.2.1
2.5Yogurtproductionareaoutlineplan
Rinse
Sink
Filling
Machine
Drain
Wash
Sink
Drain
Drainer
Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667
ColdStore
CompressorRoom
ColdStore4C
CoveredloadingArea
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Note 1: There are many different styles and types of ice cream for example: standard soft scoop, Italian, and
frozen yogurt.
Note 2: This example is based on premium ice cream from quality ingredients and whole milk; different
technologies are used to produce different ice creams.
Specialist advice should be taken from ingredients suppliers, equipment manufacturers and specialist
consultants.
3.2.4 Homogenisation
The mixture is passed through a homogenizer to break the milk fat globules into smaller sizes and aid even distribution
throughout the mix. The correct combination of temperature and homogenization pressure is important in helping to
determine the consistency of the finished product.
During the ageing process the fat crystallizes and the protein and stabilizers bind water to improve the consistency of the
finished ice cream.
Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667
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Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667
Ingredients Addition:
Manufacturing Tank
Milk
Stirring & Heating (60 700C)
Skimmed milk
powder
Sugar
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Stabilisers
Emulsifiers
Homogenization
Cooling (70C)
Aging (4 6hrs)
Holding
Colour/ Flavor Addition
Freezing/ Filling
Note: Different types /
styles of ice cream use
different types of
ingredients and recipe
timings. Please follow
your ingredient suppliers
recommendations
Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667
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Item
Note 1: The costs of various other sizes of packed ice cream can be calculated from Table 3 Cost of production of ice
cream.
For example, 50g of processed and frozen ice cream cost .. and the packaging costs about ... This
makes the total cost before profits.
With this particular product the volume of the final ice cream is larger due to incorporation of air. Therefore, a 50g of
ice cream occupies a volume of 100ml at 100% overrun. That means the container size should be approximately
110ml to fill 50g of ice cream.
Note 2: In this illustration the milk cost was ..
Note 3: These costings are a guide only. The availability and price of equipment will vary depending on the area and
time.
Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667
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Raw milk is pumped to the pasteuriser balance tank and into the regeneration section of the pasteuriser plate
pack where it is pre-heated to ~ 60 - 65C.
Whole milk processing:
The milk passes into the heating section of the plate pack where it is subjected to the legally required temperature / time
combination of 71.7C minimum for 15 seconds. It is then cooled to 5C and pumped into a holding tank.
If required, homogenisation of the pre-heated milk takes place prior to the pasteurisation stage. Homogenisation breaks the milk
fat globules into smaller sizes and distributes them evenly throughout the milk preventing them rising to the top forming a cream
line.
Skimmed Milk Processing:
The pre-heated milk at 60 - 65C exits the pasteuriser plate pack and passes into a separator, which removes
the cream. The cream is transferred to a raw cream storage tank prior to pasteurisation in a dedicated cream pasteuriser.
The skim returns to the heating section of the milk pasteurizer and is subjected to the legally required temperature / time
combination of 71.7C minimum for 15 seconds. It is then cooled to 5C and pumped into
a holding tank.
Semi-skimmed milk processing:
The pre-heated milk at 60 - 65C exits the pasteuriser plate pack and passes into a separator, which removes the cream. Some of
the cream is then blended back with the skimmed milk to provide the required butterfat content. This standardised milk is then
pumped to a homogeniser, which breaks up the fat globules into smaller pieces and distributes them evenly throughout the milk.
It is then returned to the heating section of the milk pasteuriser and is subjected to the legally required temperature / time
combination of 71.7C minimum for 15 seconds. The semi-skimmed milk is then cooled to 5C and pumped into a holding tank.
The surplus cream is transferred to a raw cream storage tank prior to pasteurisation in a dedicated cream pasteuriser.
4.2.2 Filling / Capping:
The cooled, pasteurized milk in the finished milk holding tank is pumped or gravity fed into a filling machine. Bottles are
filled, capped and have labels and codes applied prior to being crated and transferred to cold storage at less than 5C in
preparation for dispatch and sale. Product testing for compliance with legal requirements is carried out at this stage.
Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667
Raw Milk
Pasteuriser plant
Pre-heating (60 - 65C)
Pasteurisation
Cooling (5C)
(71.7C for
15 sec.)
Homogenisation
(if required)
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Separation
Holding
Standardisation
Homogenisation
(if required)
Surplus Cream
Cream Pasteurization
Filling / capping
Cream Filling/
Capping/ Label/ Code
Label / code
Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667
Note 1: Other packed sizes can be calculated using the cost of processed milk and adding the packaging cost. For
example, cost per litre of processed milk is UgX . and cost of one-litre poly bottle and cap is bout
UgX making the total cost of UgX . before profits.
Note 2: The prevailing milk price used in the example is UgX ...
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Processing
Labour
Ingredients
Equipment
Buildings
Daily admin and other running costs
Admin and maintenance
Product delivery
Building repairs
Return on capital
Return on working capital
Product storage
Sub total excluding packaging
Sub total to produce 1 litre
Packaging cost per litre
Total cost before profit
Profits at 20%
Ex-farm cost per litre
Note 3: This costing is only a guide. The availability and price of equipment may vary. Ensure you make enough
consultation before proceeding.
Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667
Hand
WashSink
PersonalLockers
ProtectiveClothing
Boiler
ChilledWaterUnit
Toilet(withhandwashsink)
Areatoremove
outsideclothing
andfootwear.
Sitonbench
swinglegsover
andputdairy
protective
clothingand
footwearon.
WashSink
Hand
Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667
Drain
AirCompressor
Past.
Milk
Tank
Raw
Milk
Tank
Drain
Drain
MilkBottle
Filling
Hydrogeniser
Seperator
Milk
Pasteuriser
Drain
Drainer
Rinse
Sink
Wash
Sink
Drainer
Cream
Filling
Cream
Batch
Past.
PackagingStore
Covered
UnloadingArea
PleaseNote:Nottoscale
Alwaysconsultyour LocalEnvironmental HealthOfficer(EHO) Planning andBuilding Regulationsatall stages.
Many production sitesproducehighquality ice cream with a simplified versionof theadove.
Fig.4.1
ColdStore4C
CoveredloadingArea
ColdStore
CompressorRoom
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Section 5 - Appendices
Appendix 1
Capital items for Yogurt manufacture, 100 litre batch per day
Building premises (7m x 3.5m) we assume that you can set up this space at home to avoid rental costs.
Capital for Equipment
Batch pasteuriser
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Separator
Walk in chilled store
Product Chiller x 2
Yogurt pump
Raw milk tank (SS)
Compressor (air)
Hot water boiler
Dish washer
Pot sealer
Buckets, jars etc
Total
Appendix 2
Capital items for ice cream manufacture, refurbished premises
(7m x 3m) you can creat this space at home to avoid rental fees
Capital for Equipment
Jacketed tanks, 100 litres x 2
Homogeniser
Continuous freezer
Pipes, fittings
Hot water boiler
Compressor (air)
Cup filler
Trays and ancillary items
Large freezer store
Total
Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667
Appendix 3
Capital items for milk pasteurisation and bottling
Building premises (8m x 3m x 2m high
Process equipment
Second-Hand
New
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Separator
Poly bottle filler
Pipes, valves, pump
Pasteurised milk tank
Hot water boiler
Compressor (air)
Batch cream pasteuriser
Total
This booklet and the information within are intended as a guide only. You will need to make further checks before you kick
off the project.
Telesat International will be happy to take a lead in the establishment of this project.
Address:
Telesat International,
Burton Street, Platinum House, 2nd Floor, Room B.3
Tel: 0312 288 120/ 0392 945 667/ 0703 056 058
E
Mail: info@telesatinternational.net
Website: www.telesatinternational.net
Telesat International Burton Street, Platinum House, 2nd Floor, Room B.3. Tel: 0392 945 667