Product and Process Development Group
Introduction
The Product and Process Development (PPD) is a research and development group that develops products, provides process technologies for product manufacturing, and mechanizes production by developing appropriate machines and equipment or adapting existing machines from other sectors. The group maintains a robust research program to develop and commercialize ready-to-use cultures for the production of fermented dairy products. The PPD Group assists dairy cooperatives and producer companies in establishing process lines, stabilizing production, providing ongoing troubleshooting support, and offering product testing training.
Objective
The primary objective of the Product and Process Development Group is to support dairy cooperatives in product diversification by providing product, process, and packaging technologies for the commercial manufacturing of value-added, innovative dairy products to meet their increasing demand.
Milestones
The PPD group has achieved significant milestones. Notable accomplishments are listed below.
1970s
- Operation Flood: Adapted Western technology, with and without modifications, for the manufacturing of recombined milk, milk powders, butter, and ghee.
- Initiated research efforts to develop process technologies for utilizing buffalo/mixed milk in the production of various milk products.
1980s
- Commercial production of Misti Doi through Mother Dairy, Kolkata
1990s
- Mechanized production and improved packaging facilitated the marketing of long-life paneer and dahi.
- Organized ice cream production within the cooperative sector.
2000s
- Mechanized production of Indigenous sweetmeats
2010s
- Initiated research in Ready-to-Use Culture (RUC) development; developed nutrition meals for nutrition-deficient populations.
- Developed World Dairy Innovation Award-winning products, including Dahi-based spread and Dahi-based fusion products.
- Developed a kit for rapid detection of adulterants in milk.
2020s
- Commercial production of RUC for dairy industry
- Development of honey and millet-based products
Details of on-going projects:
Product Development:
In recent years, our research efforts have focused on developing innovative dairy products that offer health benefits in addition to their inherent nutritional value. To achieve this, millets and honey have been extensively utilized as ingredients in various dairy products. Recipes for classic dairy products such as Kalakand, Kulfi, Peda, Sandesh, Shrikhand, Ice Cream, and Mishti Dahi have been modified by using honey as a sweetener, partially or fully replacing added sugar.
Nutritious premixes designed to combat malnutrition have been developed by integrating scientific knowledge with traditional practices. These products feature protein sources from milk, millet, and vegetables, resulting in an improved amino acid profile and enhanced bioavailability. The premixes are available in various formulations, incorporating different millet varieties, including Browntop (Andua), Foxtail (Kangni), Barnyard (Sanwa), Little (Kutki), Kodo (Kodra), Pearl (Bajra), Sorghum (Jowar), Finger Millet (Ragi), and multi-millet blends.
Process Development:
To promote milk and milk product processing at the farm/village level and create a market for farm-fresh products, NDDB, in collaboration with IDMC, has developed a process line for manufacturing dairy products for farms handling 100 litres of milk per day. This equipment line allows for the processing of a wide range of milk products, including pasteurized market milk, curd/lassi/buttermilk, khoa, ghee, paneer, and shrikhand. It is ideally suited for small cooperatives, Farmer Producer Organizations (FPOs), and dairy entrepreneurs. The first such unit has been installed by NDDB at Atithi Dairy Farm in Petlad taluka, Anand, Gujarat.
Ready-to-use Culture (RUC) Development:
India has historically relied heavily on imports to meet the dairy industry’s demand for ready-to-use cultures (RUCs). Recognizing the need and value of indigenous technology, PPD has invested over a decade of concerted effort to master this technology. This advancement has enabled us to harness the rich microbial diversity available within India. Currently, our depository houses over one hundred well-characterized starter cultures. Multiple RUC formulations for the production of fermented dairy products have been developed and successfully tested across various dairies. The RUC technology has been transferred to Ms. IDMC for commercial manufacturing and marketing.
Services to Cooperative Dairy Plants:
A significant area of PPD’s intervention is providing services to cooperative dairies across various aspects of milk and milk processing. These services include troubleshooting, ingredient and product selection, recipe upgrades, assistance with product analysis, Standard Operating Procedure (SOP) development, training in product development, starter culture management, the use of small-scale equipment for milk processing at the farm/Dairy Cooperative Society (DCS) level, and adulteration detection in raw milk.
Exhaustive list of Products/Process Technologies Developed by PPD
- Fruit yoghurt
- Misti doi and Probiotic misti doi
- Shrikhand
- Dahi
- Buttermilk
- Lassi
- Milk beverage with ragi
- Whey-based drink
- Flavoured milk
- Frozen yoghurt
- Ice cream
- Chhana kheer
- Chhana podo
- Gulabjamun
- Khoa
- Peda
- Paneer pickle
- Paneer/Long life Paneer
- Mozzarella cheese
- Cheddar cheese
- Dahi-based spread
- Processed cheese spread
- Ready-to-eat dairy-based meal
- Chaska (Chhana and Maska) Podo
- Dahi-Legume Snack
- Set Mango Dahi
- Hipro – High Protein Fermented Milk Drink
- Shrikhand-Like Fermented Product/Matha
- Dahi-Based Fusion
- Carbonated Buttermilk Fruit Juice
- Carrot Lassi
- Lassi With Tulsi Seeds
- Triphala Chhaas
- Chaska (Chhana and Maska) Spread
- Cream Fruit Spread
- Dairy-Based Energy Bar
- Milk Protein Enriched Caramel Soft Candy
- Nutrition Meal
- Ice Cream without Added Sugar
- Dairy Products made using Millets (Dahi-like fermented product, Ice cream and Nutritional Meal)
- Dairy Products made using Honey (Sweet Dahi, Ice Cream, Kalakand, Kulfi, Peda Sandesh, Shrikhand and Yoghurt)