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SSS Dairy Tech

Consultants
Trusted Dairy Plant Consulting Expertise

Turning dairy plants into profitable, efficient operations

SSS DairyTech Consultants helps dairy plants improve production efficiency, quality systems, product yield, laboratory practices, product flavour, texture, microbial quality, and profitability through practical hands-on consulting.

Visible results delivered in dairy plants:

  • Raw milk MBRT improved from 30 minutes to 150 minutes.
  • Pouch milk MBRT improved from 5.45 hours to 7.45 hours.
  • Ghee grain and flavour improved through process optimisation.
  • Curd structure and taste improvement resulted in doubled sales.
View Department KRAs Request Consultation View Training Programs
Dairy processing setup overview Modern dairy processing line Automated dairy plant operations

About the Consultant

Mr. S. Somasundaram

Mr. S. Somasundaram dairy consultant

Senior Dairy Technologist & Industry Professional.

Mr. S. Somasundaram is a senior dairy technologist and industry professional with over 45 years of experience in the dairy sector. He is a Dairy Technologist from NDRI, Bangalore and an MBA postgraduate with extensive hands-on experience in dairy plant operations, technical management, and dairy industry consulting.

He has worked with major dairy organizations including Aavin for nearly three decades, served as Plant Head at Heritage Foods India Ltd, and later as CEO of Vijay Dairy & Farm Products Pvt Ltd, Trichy, a dairy plant with a capacity of about 2 lakh litres per day including milk powder production.

Key Expertise

  • Dairy plant technical auditing and performance improvement.
  • Milk procurement system improvement and MBRT strengthening.
  • Material balance and yield optimization.
  • Quality systems implementation and microbial contamination control.
  • CIP system management, sanitation control, and chemical cost optimization.
  • Energy optimization, operational cost reduction, and daily Gemba meeting systems.

Dairy Plant Technical Audit Program

Gap analysis and improvement roadmap for quality, yield, and operating cost

Technical auditing is a major consulting area of SSS DairyTech Consultants. The program studies plant operations, identifies performance gaps, and recommends practical actions to improve quality consistency, increase yield, and reduce cost of operations.

1
Process and product flow assessment across the plant.
2
Material balance study and identification of yield losses.
3
Quality systems review including laboratory practices.
4
Utility and energy performance evaluation for steam, refrigeration, power, and water.
5
Cost of production analysis and operational loss identification.
6
Department-wise KRA review and accountability mapping.
Tech audit inspection at dairy plant
Tech Audit Inspection
Lab testing activities in dairy plant
Lab Testing
Department-wise KRA review meeting with plant team
KRA Review
Paneer production process line
Paneer Production

Detailed Information

Expandable sections for methodology, KRA, and training

To keep the homepage readable while preserving detail, the most extensive information is grouped in expandable sections below.

Dairy Plant Improvement Methodology⌄

The improvement methodology combines floor-level observation, KRA review, daily meetings, and Gemba-based action tracking to create measurable operational improvement in dairy plants.

1
Shop-floor observation and detailed line walkthrough.
2
Review of production, quality, and dispatch records.
3
Interaction and discussion with department heads and key personnel.
4
Identification of deviations, operational gaps, and root causes.
5
Daily Gemba meetings to resolve issues and improve inter-department coordination.
6
Kaizen / Continuous improvement through small daily actions for measurable operational gains.
7
Preparation and follow-up of action plans with responsibilities, timelines, and performance review.
Fishbone cause and effect analysis board
Fishbone Cause and Effect Analysis
Gemba meeting with gemba board in dairy plant
Gemba Meeting with Gemba Board
Kaizen discussions for continuous improvement planning
Kaizen Discussions
Department-wise Key Result Areas⌄

SSS DairyTech Consultants supports dairy plants in defining practical KRAs across production, quality, procurement, maintenance, packing, CIP, and sanitation.

Production – Milk

  • Cost control
  • Production efficiency
  • Product quality
  • Employee motivation

Production – By Products

  • Cost control
  • Production efficiency
  • Product quality
  • Employee motivation

Maintenance

  • Equipment reliability
  • Energy consumption
  • Cost controls
  • Preventive maintenance schedules

Procurement

  • Farm feed management
  • VLCC performance
  • MBRT standards
  • Volume procurement

Quality Assurance

  • Quality control
  • Testing efficiency
  • Training
  • Complaint reduction

Packing & Dispatch

  • On-time dispatch
  • Cold chain effectiveness
  • Correct quantity
  • Safety system

CIP System

  • CIP effectiveness
  • Chemical concentration control
  • Cleaning cycle discipline
  • Hygiene assurance

Plant Sanitation & Hygiene

  • Equipment sanitation
  • Plant hygiene standards
  • Microbial risk control
  • Cleaning verification

Stores

  • Minimum and safety stock control
  • FIFO implementation
  • Inventory accuracy and verification
  • Reduced stock value and excess inventory
  • Disposal of slow-moving stock

Purchase

  • Vendor qualification
  • Cost negotiation and benchmarking
  • Timely procurement
  • Material quality compliance
  • Coordination with stores
Training Programs for Dairy Plant Staff⌄

Structured hands-on programs are available for dairy plant managers, supervisors, laboratory staff, procurement teams, maintenance teams, and quality personnel.

  • Raw milk procurement improvement and MBRT improvement program.
  • Material balancing from milk payment to milk receipt and processing.
  • Process milk training for aroma and process consistency.
  • Good Manufacturing Practices for dairy plants.
  • Yield improvement across milk processing operations.
  • Supervisor training on process flow and critical operations.
  • Packing section training for film yield improvement and loss control.
  • Selection of packing film suppliers and purchase order requirements.
  • Energy management in dairy plants.
  • Quality laboratory training on chemical and microbiological testing.
  • Compliance with BIS and FSSAI quality standards.
  • Control of microbial contamination in dairy plants.
  • Line study techniques to identify contamination sources.
  • CIP system management and chemical selection based on water quality.
  • Development and implementation of SOPs for dairy plant operations.
  • New dairy product development including standardization and pilot trials.
CIP training session for dairy plant cleaning process
CIP Training
Energy management training for dairy plant teams
Energy Management Training
GMP training for good manufacturing practices
GMP Training

Why Choose Us

SSS Dairy Tech Advantage

Why Clients Choose SSS Dairy Tech

Trusted by dairy plants for practical, hands-on consulting that improves plant performance, product quality, and long-term operational reliability.

✓
Over 45 years of dairy industry experience
✓
Practical plant-level expertise and operational knowledge
✓
Independent and unbiased technical advisory
✓
Proven track record in improving plant performance
✓
Support from project planning to plant operations

Our Approach

SSS Dairy Tech combines technical expertise with practical industry experience to deliver solutions that are both technically sound and operationally feasible.

Understanding client operational challenges
Identifying practical improvement opportunities
Implementing technically reliable solutions
Supporting long-term operational sustainability

Services

Professional consulting and technical auditing for dairy plants

Technical Auditing of Dairy Plants

Detailed plant assessment covering process flow, material balance, yield loss points, quality gaps, utility performance, and cost reduction opportunities with a practical improvement roadmap.

Process system review for technical auditing of dairy plants
Technical Auditing

Dairy Plant Process Optimization

Improvement of processing parameters, product flow, equipment utilization, and shop-floor discipline to achieve better consistency, lower losses, and smoother daily operations.

Dairy plant auto valve operation system for dairy process optimization
Dairy plant auto valve operation system

Yield Improvement for Butter, Ghee & Paneer

Focused technical support to improve fat recovery, moisture control, process handling, and product standardization for better yield and profitability.

  • Material balance review to identify hidden yield losses.
  • Process parameter tuning for consistent product recovery.
  • Packing and handling controls to reduce avoidable wastage.
Process efficiency improvement for dairy yield enhancement
Yield Improvement

Quality Systems & Laboratory SOPs

Development and strengthening of laboratory systems, testing discipline, documentation, and quality control procedures aligned with dairy plant requirements.

Laboratory SOP documentation and quality control procedures for dairy plants
Laboratory SOP

SOP Development & Implementation

Preparation of clear SOPs for production, quality, sanitation, packing, utilities, and handling operations with hands-on implementation support.

Five reasons why standard operating procedures are needed in dairy plant operations
SOP Implementation

New Dairy Plant Advisory

End-to-end advisory for new dairy projects including planning, process selection, utility integration, vendor coordination, installation review, and commissioning support.

New dairy plant advisory support for planning and commissioning
New Plant Advisory

ERP for Milk Procurement & Tracking

Support in structuring procurement monitoring systems for better tracking of quantity, quality, payment accuracy, route control, and procurement efficiency.

ERP and process tracking dashboard for milk procurement monitoring
ERP & Tracking

Energy & Operational Efficiency

Assessment of steam, refrigeration, electrical power, compressed air, water, and utilities to identify practical measures for reducing operating cost.

Energy management and operational efficiency improvement in dairy plants
Energy Efficiency

New Dairy Product Development

Consulting support for concept development, formulation, process standardization, pilot trials, stability improvement, and commercialization.

Product formulation and evaluation for new dairy product development
Product Formulation and Evaluation

Key Achievements

Measured improvements delivered through practical implementation

MBRT improvement in milk quality process
MBRT improvement
Milk packing film yield improvement
Milk packing film yield improvement
Curd structure improvement in fermented dairy products
Curd structure improvement

Achievement

Ice Cream Plant Installation

1000 litre/day plant

Successful installation and commissioning of a 1000 LPD ice cream plant producing natural and regular ice creams including cones, cups, family packs, kulfi varieties, and special flavours.

Achievement

Raw Milk MBRT Improvement

30 min → 150 min

Improved raw milk quality through procurement discipline, MBRT monitoring, and hygiene control at collection level.

Achievement

Pouch Milk MBRT Improvement

5.45 hrs → 7.45 hrs

Enhanced processing hygiene, CIP effectiveness, and packing line sanitation to improve microbial quality of pouch milk.

Achievement

Ghee Grain & Flavour Improvement

Product quality uplift

Optimized ghee processing parameters to improve grain formation and flavour, resulting in stronger consumer acceptance.

Achievement

Curd Structure & Taste Improvement

Sales doubled

Improved fermentation control and culture management leading to better body, texture, and taste with significantly increased market demand.

Achievement

Packing Film Yield Improvement

10–12% improvement

Reduced packing losses and improved material utilization through operational control.

Client Engagements

Representative consulting assignments

SSS DairyTech Consultants has supported dairy plants across India and internationally in areas such as plant operations improvement, MBRT improvement, product quality enhancement, process optimisation, and dairy plant project advisory.

Major Dairy Clients

  • VKA Milk – Karur
  • Sri Mahalalakshmi Dairy – Aroma Milk, Coimbatore
  • Winner Dairy – Rusi Milk, Pondicherry
  • White field dairy- Amrut milk Pollachi
  • Ruby Milk – Madurai
  • SMD Milk – Erode
  • Jallikattu Milk – RKR Dairy Products
  • SNP Milk – Madurai

Online Technical Support

  • Sandeep Paneer – Mysore
  • Mastany Lassi – Khandwa, Madhya Pradesh
  • Fish Tail Dairy – Pokhara, Nepal
  • Alvas Dairy – Singapore
  • Velan Foods – Madurai

New Dairy Projects

  • VKA Dairy Karur – 300,000 LPD fully automated multi-product dairy plant

Major Ongoing Project

₹150 Crore fully automated integrated dairy plant

SSS DairyTech Consultants is currently associated with a major dairy project involving the development of a fully automated integrated dairy processing plant with PLC-based process control and SCADA monitoring systems.

Milk pouch packing
Sterilized milk processing
Milk powder production
Butter production
Ghee manufacturing
Yogurt / fermented milk products
Paneer production
Ice cream production
Curd production in pouch, cup, and bucket packs

Automation, Utilities & Advisory Scope

  • PLC-based process control systems.
  • SCADA-based plant monitoring and supervisory control.
  • Integrated automation across processing and utility systems.
  • Boiler, steam, refrigeration, compressed air, CIP, and electrical utility integration.
  • Advisory support in project planning, process flow design, machinery selection, layout planning, and commissioning support.
Centralized process monitoring SCADA systems
Centralized Process Monitoring - SCADA Systems
SSS DairyTech footer logo

SSS DairyTech Consultants

Consulting across India and internationally.

Mobile +91-9944427435,
+91-9443575974 Email sssdairytech@gmail.com Address Sundaranivas, 14 Vallal Alagappar Street, Navarathina Nagar, Karaikudi - 630 002, Tamilnadu, India
Focus Areas Technical audit, process optimization, yield improvement, SOPs, training, quality systems, and new dairy project advisory.

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