Every batch of Poornam Dairy milk follows a strict, documented 12-step process — from raw milk collection through HTST pasteurisation to cold-chain delivery. Nothing is left to chance.
As per FSSAI License Condition No. 8, all production steps must be recorded. Poornam Dairy maintains a comprehensive record system across 14 register types — and all pasteurisation charts are retained for a minimum of 6 months.
Collected from registered farmers only. Every batch is tested at source — Clot-on-Boiling (COB) test, Lactometer CLR reading (minimum 26), acidity (max 0.14% lactic acid) and visual quality check. Only milk meeting all parameters is accepted.
Milk Collection Register: date, farmer name, FSSAI registration no., quantity, COB result, CLR, acidity, temperature, acceptance/rejection, payment
Milk received at the processing plant undergoes temperature verification and a rapid adulteration panel — checking for neutralizers, starch, detergent, urea and water addition. Fat percentage verified by Gerber test.
Raw Material Receipt Register: vendor details, quantity, vehicle no., temperature, test results, lot no.
Raw milk is passed through muslin/filter cloth or mechanical clarifier to remove foreign matter and somatic cells. The filter is cleaned and sanitised after each batch.
If milk is not processed the same day, it is chilled to 4°C or below within 2 hours of collection in our stainless steel 1,000 litre Bulk Milk Cooling Center (BMC). Temperature is recorded every 2 hours.
Chilling Temperature Log: time and temperature entries every 2 hours
Milk fat and SNF adjusted to FSSAI required standards for each product type using cream separator and standardiser. Pearson Square method used for calculations. Cow Milk: Fat ≥ 3.5%, SNF ≥ 9.0%.
Standardisation Worksheet: initial fat %, target fat %, cream separated quantity, final fat % and SNF % verified
2-stage homogeniser: 1st stage at 150 bar, 2nd stage at 40 bar, at 60–65°C. Prevents cream separation in packed pouches and improves texture and mouthfeel.
HTST (High Temperature Short Time) pasteurisation at exactly 72°C for minimum 15 seconds. Flow diversion valve (FDV) operation is verified on each batch. Post-pasteurisation Phosphatase test must be NEGATIVE — confirming adequate heat treatment. Peroxidase test should be POSITIVE — confirming no over-heating.
Pasteurisation Temperature Recorder Chart (thermograph): continuous temperature trace; start time, temperature, end time, any diversions
Milk is cooled immediately after pasteurisation to below 4°C in a plate heat exchanger. Temperature is not allowed to rise above 4°C before packaging. Any temperature exceedance is treated as a batch-hold event.
Filled into virgin food-grade plastic pouches (500ml / 400ml / 800ml as appropriate). Each pouch is sealed with impulse sealer. Batch No., Date of Manufacture, Use By Date and MRP are stamped on every pouch. Fill weight checked (500g ±5g per Legal Metrology Rules).
Packaging Register: date, batch no., pack count, fill volume check results, seal quality, stamps verified
5 pouches checked per batch: seal integrity, fill volume, stamp legibility, no leakage. Sensory check — colour (white/pale yellow), odour (pleasant, clean), no off-flavour. One sealed pouch retained from each batch as reference sample.
Packed pouches stored at 4°C or below. FIFO (First In First Out) stock rotation. Temperature logged minimum 3 times daily — morning, afternoon and evening. Cold room never stores strong-odour products alongside dairy.
Transported in refrigerated vehicles or insulated containers with ice packs — maintaining below 4°C throughout transit. Sold only to FSSAI registered distributors and retailers. Dispatch register records buyer FSSAI number, invoice and temperature at dispatch.
Dispatch Register: buyer name, FSSAI registration no., quantity, batch no., vehicle no., temperature at dispatch, invoice no.
Per FSSAI License Condition No. 8, Poornam Dairy maintains complete production records. All records are available for inspection at the premises.
Date, farmer, FSSAI no., quantity, COB, CLR, acidity, temp, acceptance/rejection.
Continuous thermograph of HTST temperature — one chart per production day.
Batch no., raw milk quantity, standardisation calculations, pasteurisation records, packed quantity.
Minimum 3 readings per day — morning, afternoon, evening. Temperature in °C.
Buyer name, FSSAI no., quantity, batch no., vehicle, temperature at dispatch, invoice no.
All NABL/external lab test reports filed batch-wise: composition, microbiological, adulteration.
Per FSSAI License Condition No. 12 — products are tested at NABL-accredited laboratories at minimum once every 6 months. All test reports maintained at premises for inspection.
Fat %, SNF %, protein, lactose, total solids, acidity, CLR, specific gravity — compared against FSSAI standards every 6 months.
Total Plate Count, Coliform count, E. coli, Staphylococcus aureus, Salmonella, Listeria, Yeast & Mould — all tested per FSSAI milk safety standards.
Neutralizers (Na₂CO₃, NaOH), starch, detergent (SLS), urea, sucrose, salt, antibiotic residue (beta-lactam screen) — zero tolerance policy.
Alkaline phosphatase test performed on each batch of pasteurised milk. Must be NEGATIVE — confirming adequate pasteurisation temperature was achieved.
Full nutritional profiling at NABL lab — Energy, Fat, Saturated Fat, Trans Fat, Carbohydrates, Sugar, Protein, Sodium, Calcium — validates all label declarations.