Britania Report

8/11/2019 Britania Report

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COMPANY OVERVIEW

The story of one of India's favorite brands reads almost like a fairy tale.

Once upon a time, in 1892 to be precise, a biscuit company was started in a

nondescript house in Calcutta (now Kolkata) with an initial investment of

Rs. 295. The company we all know as Britannia today.

The beginnings might have been humble-the dreams were anything but. By

1910, with the advent of electricity, Britannia mechanized its operations,

and in 1921, it became the first company east of the Suez Canal to use

imported gas ovens. Britannia's business was flourishing. But, more

importantly, Britannia was acquiring a reputation for quality and value. As

a result, during the tragic World War II, the Government reposed its trust in

Britannia by contracting it to supply large quantities of "service biscuits" to

the armed forces.

As time moved on, the biscuit market continued to grow and Britannia

grew along with it. In 1975, the Britannia Biscuit Company took over the

distribution of biscuits from Parry's who till now distributed Britannia

biscuits in India. In the subsequent public issue of 1978, Indian

shareholding crossed 60%, firmly establishing the Indianness of the firm.

The following year, Britannia Biscuit Company was re-christened Britannia

Industries Limited (BIL). Four years later in 1983, it crossed the Rs. 100

crores revenue mark.

On the operations front, the company was making equally dynamic strides.

In 1992, it celebrated its Platinum Jubilee. In 1997, the company unveiled

its new corporate identity - "Eat Healthy, Think Better" - and made its first

foray into the dairy products market. In 1999, the "Britannia Khao, World

Cup Jao" promotion further fortified the affinity consumers had with 'Brand

Britannia'.


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Britannia strode into the 21st Century as one of India's biggest brands and

the pre-eminent food brand of the country. It was equally recognized for its

innovative approach to products and marketing: the Lagaan Match was

voted India's most successful promotional activity of the year 2001 while

the delicious Britannia 50-50 Maska-Chaska became India's mostsuccessful product launch. In 2002, Britannia's New Business Division

formed a joint venture with Fonterra, the world's second largest Dairy

Company, and Britannia New Zealand Foods Pvt. Ltd. was born. In

recognition of its vision and accelerating graph, Forbes Global rated

Britannia 'One amongst the Top 200 Small Companies of the World', and

The Economic Times pegged Britannia India's 2nd Most Trusted Brand.

Today, more than a century after those tentative first steps, Britannia'sfairy tale is not only going strong but blazing new standards, and that

miniscule initial investment has grown by leaps and bounds to crores of

rupees in wealth for Britannia's shareholders. The company's offerings are

spread across the spectrum with products ranging from the healthy and

economical Tiger biscuits to the more lifestyle-oriented Milkman Cheese.

Having succeeded in garnering the trust of almost one-third of India's one

billion populations and a strong management at the helm means Britannia

will continue to dream big on its path of innovation and quality. Andmillions of consumers will savour the results, happily ever after.


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ACKNOWLEDGEMENT

Through this acknowledgment, we express our sincere

gratitude to Mr.Prakash Pandey, Regional HR Manager, &

Mr.Rana Roy , Factory Manager, Britannia Industries

limited for providing our an opportunity to do our

summer training . This project bears on imprint of many

peoples. We sincerely thank to our project guide Miss.

Mayuri, Mr C.N Nagesh, Regional Quality Assurance

Manager & Mr. Khokan Gautam, Ekorshi Sir, Chiranjib Sir&

other quality officers for guidance and encouragement in

carrying out this project work. we also wish to express our

gratitude to the officials and other staff members ofBRITANNIA INDUSTRIES LIMITED who rendered their

valuable time to help us during the period of our summer

training and made it a worthwhile experience & we extend

our thanks to the various people who have shared their

opinions and experiences through which we received the

required information crucial for this report. Our specialthanks to Jennifer Sawney, HR Dept. of the company for

their kind co-operation to the completion of our summer

training. Last but not least we wish to avail ourself of this

opportunity, express a sense of gratitude and love to our

teachers and our beloved parents for their manual

support, strength, and help and for everything.


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CONTENTS

1) GENERAL STORE:

1.1) introduction

1.2) Purpose

1.3) Process flow

1.4) Work undergoing in the general store

1.5) Material receipt and issue

1.6) Storage condition of different material

1.7) Precautions to be taken in general store.

2) QUALITY CONTROL:

2.1) Test performed for raw materials

2.2) Finished products

2.3) Packaging materials

2.4) Determination of moisture

2.5) Determination of sedimentation value

2.6) Determination of ash content

2.7) Determination of alcoholic acidity

2.8) Determination of acid insoluble ash

2.9) Determination of germ oil acidity


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2.10) Determination of dough raising capacity

2.11) Determination of peroxide value

2.12) Determination of iodine value

2.13) Determination of Free Fatty Acid

2.14) Quality analysis of laminate

2.15) Quality analysis of CBB

3)PROJECT REPORT ON VARIATION OF MOISTURE

CONTENT AND WEIGHT OF BISCUITS IN THE PROCESSLINE

4) PRODUCTION:

4.1) Flow sheet

4.2) Mixing & mixers

4.3) Forming

4.4) Baking

4.5) Parameters

4.6) Changes during processing and baking

4.7) Biscuit processing:

i) Cream Cracker

ii) Marie Gold

iii) Tiger Crunch Choc chips

iv) Good Day Butter

5)PACKAGING:


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5.1)

Introduction

5.2) Flow sheet

5.3) Metal detector

5.4)

Stacker

5.5) Feeding Chute

5.6) Horizontal flow wrap

5.7) Packing in CBB

5.8) Defects of biscuit packaging

5.9)

Precautions taken during packaging

6)DESPATCH

7)CONCLUSION


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GENERAL STORE

INTRODUCTION:

Before the dawn of reforms era, Indian farmers used to dream ofhavi ng a roof over their head. But, things are changing fast. Now,

Indias farming community wants a roof overtheir harvested and

milled crops. Lack of proper storage facilities leads to attacks by

pests and other organisms. The damage caused through such

infestations leads to a reduction in market value depending upon

the extent of damage. In some cases the produce is declared unfit for

consumption and has to be destroyed. This leads to huge loss for the

farmer. Ware housing and transportation forms the backbone supply

chain of all industries. Adequate storage capacity and st rategic

location of the warehouse enables efficient functioning of supply

and distribution network and al so provides strategic competitive

advantage to the business.

Proper material handling, storage conditions and timely movement ofgoods are necessary as improper handling and prolonged storage

can deteriorate the quality of the stored product especially theperishables goods, biological drugs and food stuffs. As commodities trade

entered a new phase in India, it is in the warehousing sector that

India is seeing a parallel boom. Thanks to huge demand for various

agricultural products due to increasing delivery system in market and

growth that is taking place across the country; warehousingcompanies like CWC are not only increasing their capacity but scaling

up the quality of their storage space. Since warehouses need large tracts ofland, private investment is drying up. Losses during storage operation


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accounts for 6-7 % of production in food grain and 20 to 30% in case of

flour.

PURPOSE:

Scientific storage of produce from the vagaries of weather,

rodents, insects and pests.

They prevent quality and quantity losses.

Meeting the financial needs of industry who store the produce

by providing value for the goods stored.

More goods from the buffer are released when supplies are

less and less is released when supplies are more in the production

area.

Materials or goods are also transferred from here for the purpose ofInter Factory Transfer.

PROCESS FLOW:

OK NOT OK

NOT OK

OK

VENDOR

RAW PACKING

PHYSICAL INSPECTION OF

TRUCKS & RAW MATERIAL

MATERIALUNLOADED REJECTED

ANALYSIS AS PER

BIL STANDARD

ISSUED TO

PRODUCTIONPROCESSING


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WORKS UNDERGOING IN THE GENERAL STORE:

There are a series of processes through which the raw material incominginto the industry goes through before getting issued into the production.

They include the following steps:

1) RECEIVING

2) WEIGHMENT

3) STORAGE &

ISSUANCE

RECEIVING:- There is a particular unloading procedure for each and

every raw material coming into the factory. At first at least 5 random bags

are collected and are samples from them are tested in the quality control

laboratory of the factory, mainly flour are tested on the basis of the

presence of weevil or larvae, SV(sedimentation value) and moisture

content, Butter, FCCM (full cream condensed milk), and other liquid

materials are being tested for its acidity (mainly) & organoleptic qualitiesand then on the basis of that report, further the total quantity of the

materials are unloaded and stored for further use.

WEIGHING:- There are two types of weighing procedure in this industry,

they are:

Weigh bridge: if the weight

(to be measured) is more than 30ton, this procedure is applied. Here

at first the truck along with the raw materials inside it is loaded onto


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the weigh bridge and the reading is taken along with the truck

number and date. Next reading in the same process is taken after the

same truck is unloaded or emptied. Then both the readings are

subtracted along with the weight of the bags, and the net amount of

the raw materials are obtained. E.g. the weight of the flour, sugar, andother solid raw materials are taken this way.

Weighing machine: in this

machine, raw materials less than 30ton are weighed and issued for

storage or process line. The procedure is simple as taking weight. E.g.

The weight of laminate rolls, CBB (card board boxes) & liners, tapes

etc.

STORAGE AND ISSUANCE:After they are tested ok by the receiving

and weighing processes, they are then stored for storage or issued as per

requirement to the production or packaging section of the industry. Other

materials not been required at that moment go for storage either into the

factory store, or CWC (Central Welfare Corporation) or sent as per

requirement for the IFT (Inter Factory Transfer).

MATERIAL RECIEPT AND ISSUE:

There are certain procedures for materials receipt and issue. The materials

before unloading undergo a pre-unloading inspection for raw materials.

They are as follows:

All the materials in the truck

should be properly covered with tarpaulin

Tarpaulin should also be

present at the bottom of the truck also.


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Hygiene condition of the

truck should be neat

Tankers carrying edible oils

should not carry hazardous chemicals or petroleum products.

Trucks should have pollution

control check certificate.

All the materials should be

visually inspected for any physical damage/odour.

CBBs should be checked for

wet condition & damage.

Wrapper should be checked

for odour and damage.

STORAGE CONDITION OF RAW MATERIALS:

CLASS OF

ITEM

INGREDIENT NAME RECOMMENDED

STORAGE

TEMPERATURE

STORAGE

PERIOD

FLOUR i)Wheat flour

ii)Rice flour

iii)Soya flouriv)Vitacel

Room temperature

Ac condition

Ac conditionAc condition

15 days

45days

2months12months

STARCHES i)arrowroot starches

ii)maize starches

Room temperature

Room temperature

3months

6monthsFATS/OILS RBD Palmolein bulk

& RPO

Ambient temperature 1month

SWEETENI

NG

AGENTS

i)crystal sugar

ii)PG sugar

iii)Jaggery

iv)Liquid glucose

Room temperature

Room temperature

Room temperature

Room temperature

24months

2months

2months

3months


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CLASS OF ITEM INGREDIENT NAME RECOMMENDEDSTORAGE

TEMPERATURE

STORAGEPERIOD

YEAST/COLOU

RS /ENZYMES

i)Compressed yeast

ii)Pappain

iii)inactive dried

yeast

iv)Neutrase

3-7 degree Celsius

Ac room condition

Room temperature

25degree Celsius

5degree Celsius

5days

8months

6months

3months

12months

FLAVOURS i)ethyl vanillin

ii)butter flavor

iii)cocoa extender

iv)synthetic flavor

v)coconut milk

powder

vi)Dessicated

coconut powder

vii) vanillin

Ac condition

Ac condition

Ac condition

Ac condition

Ac condition

Ac condition

Ac

condition

18months

6months

6months

12months

6months

6months

24months

EMULSIFIER i)lecithin

ii)GMS

iii)Solbake

iv)Datem

Room temperature

Room temperature

Room temperature

Ac condition

6months

6months

12months

9months

ANTIOXIDANTS i)TBHQ

ii)BHA

Ac room condition

Ac room condition

36months

18months

DAIRY

FOOD

i)butter

ii)SMP

iii)condensed milk

iv)FCCM

v)whey powdervi)butter oil

0 to 10degree Celsius

-15 to -20 degree Celsius

Room temperature

Room temperature

Ac condition

Room temperatureRoom temperature

12 degree Celsius

1month

6months

9months

2months

3months

2months3months

6months max

(in drums).


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CHEMICAL &

AERATING

AGENTS

i)Ammonium

carbonate

ii)sodium carbonate

Room temperature

Room temperature

6months

6months

CHEMICALS i)citric acid

ii)sodiummetabisulphite

iii)sodium chloride

iv)propylene glycol

Room temperature

Room temperature

Room temperature

Room temperature

24months

3months

6months

3months

OTHERS i)cashew pieces &

nuts

ii)all essences

Room temperature

or ac condition

Ac condition

3months

12months

COLD STORES: The storage of things in an artificially cooled place forpreservationwhich are of two types:-

a) Cold store having a temperature of 16-17 degree Celsius: Here the

essences, FCCM, other dairy products, emulsifier and sometimes formed

dough are also kept.

b) Cold store having temperature of 3-5 degree Celsius: here only

compressed yeast and Choc-chips are kept exclusively.


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GENERAL PRECAUTIONS OF STORES:

1) Materials (ingredients, packaging material, finished goods) should not bein direct contact on the floor and should be kept in a non-permeable

material (e.g. sheets or pallets) to prevent floor seepage.

2) Minimum 18inch gap between the wall & each stack should be

maintained.

3) Each consignment is identified with a a tag indicating the date of receipt,

variety, supplier name & quantity received.

4) All the stocks issued to mixing/packing floor & CP centers will be on the

basis of FIFO (first in first out) basis, except the wheat flour which is based

on the properties of the flour & not by receipt date.

5) Each consignment should be identified with paper tag inserted in a

metal/PVC frame/sticker.

6) Bulk storage tank cleaning of the oil stored tanks should be done once in

six months.

7) All the materials should be neatly & properly arranged, and proper

ventilation and humidity should also be maintained.

8) Pest menace and hygiene should be controlled effectively.


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2 QUALITY CONTROL

AND ANALYSIS LABORATORY

TESTS PERFORMED FOR THE VARIOUS RAW

MATERIALS:

FLOUR REFINED

PALM

OIL

FULLCREAM

CONDEN

SED

MILK

YEAST LACTOSE

BUTTER

LECITHIN

SKIMMILK

POWD

ER

CHOCOLATE

CHIPS

Moisture Free

fatty

acid

Moisture Moistu

re

Moistu

re

Moistu

re

Moistu

re

Moistu

re

Moisture

Sediment

ationvalue

Peroxid

e value

Acidity Dough

raisingcapacit

y

pH Acidity Acid

value

Titrabl

eacidity

Count

per kg

Drygluten

Iodinevalue

Ash Total fat

Ash Presenc

e of

TBHQ

Acid

insolubleash

Alcoholic


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acidity

Germoil

acidity

TESTS PERFORMED FOR THE FINISHED PRODUCT:

BISCUIT

Moisture

Free fatty acid

TESTS PERFORMED FOR THE PAKAGING MATERIALS:

CBB LAMINATE

Physical parameters Physical parameters

Dimension Cut off &width

G.S.M G.S.M

Moisture Bond strength

Compression strength Tensile strength

Seal strength

AIM: DETERMINATION OF MOISTURE

PROCEDURE:About 5 g of the sample was weighed in to a petri platewhich was previously weighted. Then it was dried in an oven. The petri

plate was covered and was transferred to dessicator and weighed

quickly as possible as the dish was cooled. The heating and weighing

procedures was repeated until successive weight did not differ by more

than one milligram .Loss in weights were recorded.

Moisture % = [(M1M2)*100]/M1M

M1= weight in gm of petriplate with sample initially

M2=weight in gm of petriplate with sample after drying

M = weight in gm of sample taken


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SIGNIFICANCE:It is determined to ensure its shelf life and the packaging. If

moisture content is beyond the limit, it is prone to chemical and microbial

spoilage. It also affects the organoleptic properties.

NAME OF ITEM WEIGHT OF

MATERIAL IN

GRAMS

TEMPERATURE

IN C

TIME IN HOURS

Wheat flour 5-10 130-135 1.5

Sugar 10-15 100-105 3.0

Refined oil 20 100-105 1.0

SMP 5-10 98 5.0Biscuits 5-10 100-105 4.0

STANDARD SPECIFICATIONS:

NAME OF

ITEM

Wheat

flour

Skim

milk

powd

er

Choco

late

chips

FCCM Yeast Lact

ose

Butt

er

Lecith

in

Biscuit CBB

ACCEPTAN

CE

CRITERION

14%

max

5%

max

2%

max

29%

max

75%

max

0.5

%

max

16%

max

2%

max

Good day,

Tiger

crunch-

1.75+- 0.25

% max and

Cream

cracker-

2+- 0.25%

max

7-9%

max

AIM: DETERMINATION OF SEDIMENTATION VALUE

PROCEDURE: In a stoppered measuring cylinder (sedimentation shaker),

3.2 gm of flour was taken. To it added 50ml of Bromophenol Blue solution

and shake for 5mins. After that, 25ml of Isopropanol Lactic Acid solution

was added and shaken for another 5mins. Then kept the cylinder in a

standing position on a table for 5mins and noted the height of precipitate.

STANDARD SPECIFICATION: 19 to 25 is the acceptance criterion.


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AIM: DETERMINATION OF GLUTEN CONTENT

PROCEDURE: Weighted accurately 25gms of sample in a 100ml beaker.

Made a round ball of dough using 15ml of distilled water. Transferred thedough ball to a container filled with water and allow it to stand for an hour.

Remove the dough and wash it in a gentle stream of tap water over a sieve

of fine mesh till the water passing through the sieve is free from starch.

Then place the wet gluten in porcelain dish after cutting it into small pieces

and then dry it in a hot air oven at 135C for 2hrs. Cooled and weighted the

sample.

Dry gluten % = [(W2W) x 100 x 100] / [25 x (100 M)]

W2= weight of petriplate and gluten after drying

W = weight of petriplate

M = moisture percent of flour

STANDARD SPECIFICATION: 7.5gms minimum is the acceptance

criterion.

AIM: DETERMINATION OF ASH CONTENT

PROCEDURE: The empty silica crucible is weighted and 3-5gm of sample

was taken and weighted again. Then it was placed in muffle furnace at 550-

600C for 5-6hrs. Then sample is allowed to cool overnight in the furnace.

Placed the sample in the dessicator and then weighted. The difference in

weight of sample before and after ashing gives the ash content of the

sample.

Ash % = [100(W2 W1)]/W

W2= weight in gm of the dish with ash

W1=weight in gm of the empty dish

W =weight of the sample taken for the test


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STANDARD SPECIFICATIONS:1% max for flour and 0.3% max for lactose

is the acceptance criterion.

SIGNIFICANCE: It is determined to check the presence of mineral and also

to check that no adulteration has taken place.

AIM: DETERMINATION OF ALCOHOLIC ACIDITY

PROCEDURE:Weighted 5gm of sample in a conical flask and add 50ml of

neutral alcohol. Closed the flask and allowed it to stand for 24hrs. Filter the

alcoholic extract through an ordinary filter paper. Titrate 10ml of filtrate

with standard N/10 NaOH using phenolphthalein as indicator. Calculate %

acidity in terms of Sulphuric acid.

Alcoholic acidity% = (24.52 x A x N)/W

A= Volume in ml of standard NaOH solution used in titration after deducing

blank for 10ml of alcohol

N= Normality of standard NaOH

W= Weight in gm of the material taken for the test

STANDARD SPECIFICATIONS: 0.12% max for flour in the acceptance

criterion.

AIM: DETERMINATION OF ACID INSOLUBLE ASH

PROCEDURE: To the ash in the dish, 25ml 6(N) HCl is added. It is coveredand heated on water bath for 10mins. It is allowed to cool and the contents

are filtered through a gravimetric filter paper. The filter paper is washed

with distilled water till washing is free from acid. The filter paper is ashed

and weighted in the same dish.

Acid insoluble ash % = [100 x (W2-W) x 100]/[(W1-W) x (100-M)]

W2= Weight in gm of the dish with acid insoluble ash

W1= Weight in gm of the dish with material taken


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W = Weight in gm of empty dish

M = Moisture % in sample

STANDARD SPECIFICATIONS:0.1% max for flour and for lecithin is the

acceptance criterion.

SIGNIFICANCE: Acid insolubleash is determined to check the presence of

silica and heavy metal salt content.

AIM: DETERMINATION OF GERMOIL ACIDITY

PROCEDURE:5gm of sample is weighted and added to an iodine flask

followed by 50ml petroleum ether. The flask is closed and allowed to standfor 24 hrs. A conical flask is weighted and the contents of the iodine flask

are filtered in it. The conical flask is placed on the water bath for as long as

it is not free from petroleum ether. The flask is cooled and weighted to

know oil content. Neutral alcohol is added to the germ oil in conical flask

and titrated against N/10 NaOH using phenolphthalein indicator.

Germoil acidity% = [(T-B) x actual strength of NaOH x 28.2]/(W2W1)

T= Titre for Germoil

B= Titre value for blank

W2-W1= Weight of Germoil extracted

STANDARD SPECIFICATION:17.5% max for Good Day and classic cookies

and 20.0% max for others.

AIM: DETERMINATION OF DOUGH RAISING CAPACITY OF YEAST

PROCEDURE: About 1gm of dried yeast or 4gms of compressed fresh yeast

weighed accurately into a 100ml dry beaker. To that 1-1.5gm of sugar is

mixed and dissolved in 55ml of hot water maintained at 40C.

Dough is prepared by mixing the yeast suspension with 100gms of wheat

flour. The prepared dough is uniformly packed inside a 500ml dry beaker

dough height (A) is measured from the bottom and the allowance must begiven for the bottom thickness of the glass.


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The beaker is covered with watch glass giving room for the dough to be

equilibrium with atmosphere for 1hr duration. After 1hr the increase in

height of the dough is measured.

Dough raising capacity= [(B A) *100]/A

A=Initial height

B=Final height of the raised dough.

STANDARD SPECIFICATION:125min is the acceptance criterion

AIM: DETERMINATION OF PEROXIDE VALUE

PROCEDURE:About 2-3gms of the sample is accurately weighted in a dried

250ml Iodine flask. To that 25ml of the solvent (Mix 2 volumes of glacial

acetic acid and 1volume of chloroform) is added and mixed

homogeneously. 1ml of Potassium iodine solution is added and allowed to

stand in the dark for 1minute. After 1minute, 1ml of starch indicator is

added and the solution is diluted with 35ml of distilled water and titrated

against 0.002N solution of sodium thiosulphate from 10ml volumetric

burette. The end point is the disappearance of blue colour. A blank with25ml of Chloroform- acetic acid mixture is carried out.

P.V= [1000(V1V2) x N]/W

V1= Volume in ml of sodium thiosulphate used in test

V2= Volume in ml of sodium thiosulphate used in blank

N = Normality of sodium thiosulphate

W = Weight of sample

STANDARD SPECIFICATION: 1.5 max for Refined Palm Oil

SIGNIFICANCE:Peroxide value is the milli equivalent of peroxide per kg of

fat.


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0.1N KOH drop by drop until a faint but permanent pink colour appears.

Then the mixture of oil and neutral alcohol is heated in a hot water bath.

Then titrate the hot solution (between 50and 60C) rapidly with 0.1N KOH,

to the first pink colour which remains for 15 seconds.

Free Fatty acid = [(V2V1) x N x 56] /W

V1= Volume in ml of KOH solution in test

V2= Volume in ml of KOH solution in blank

N = Normality of KOH solution

W = Weight of sample

STANDARD SPECIFICATION: 0.10% max for RPO

SIGNIFICANCE: It is determined to check whether the sample is prone to

rancidity.

AIM: QUALITY ANALYSIS OF LAMINATE

PARAMETERS SAMPLE SIZE METHOD OF

CHECKING

ACCEPTANCE

CRITERION

Generalcharacteristics

As per samplingplan

Physicalobservations/

organoleptic

evaluation

Should be free from

Hook mark, Coredamage, Pin hole,

Foreign odour and

should be food grade

Declaration of a) veg

logo

b)manufacturing

address

c)ingredientsd)best before

As per sampling

plan

Visual

a) Veg logo

should be

present

b) Ingredients

used should be

mentioned

c)

To match withapproved

reference

sample

d) Best before

should be

present.

Dimension width x

cut off

As per sampling

plan

With calibrated

steel scale

As per specification

GSM As per samplingplan

Average weights of

wrapper pieces cut

by standard metaltemplate (10cm x

10cm)

Actual GSM beyond

standard GSM + 3%

subject to pricededuction and

beyond +- 5% subject


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to rejection.

Bond strength As per sampling

plan

By declaration of

vendor in test

certificate

80gm or 15mm

minimum

Seal strength Cut into 25mm x

100mm

By universal tensile

tester

300-500gm per 25m

AIM: QUALITY ANALYSIS OF CBB:

PARAMETERS SAMPLE SIZE METHOD OF

CHECKING

ACCEPTANCE

CRITERION

General

characteristics

As per sampling

plan

Physical

observations/

organoleptic

evaluation

Should be dry,free

from damage and

foreign odour

Declaration of a)

stacking norms

b) net weight

c) whole sale pack

As per sampling

plan

Visual

a)

should be

present

b) should be

mentioned

c) should be

present

Dimension

CBB- LxWxH

As per sampling

plan

With calibrated

steel scale

Specification, +- 2mm

from each sie.

Dimension as per

package standard

GSM (both total GSM

and individual layer

GSM)

As per sampling

plan

Average weights

of board pieces

cut by standard

metal template

Min. value- standard

GSM ( - ) 5%

Compression

strength

As per sampling

plan

Compression

strength machine

For good day- 150-

155

For tiger krunch- 125-

120

For cream cracker-

120


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PROJECT REPORT

ON

THE VARIATION OF

MOISTURE CONTENT AND

WEIGHT OF BISCUITS IN

THE PROCESS LINE


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AIM:

TO DETERMINE THE VARIATION OF MOISTURE CONTENT OF BISCUIT IN

THE PROCESS LINE

THEORY:

Water contentor moisture contentis the quantity ofwater contained in a

material. Water content can be directly measured using a known volume of

the material, and a dryingoven.

Moisture in inappropriate amounts and places is very damaging to the

useful life of food. Because of this, much effort is put into reducing thewater content of dry foods in order to prolong their shelf lives. Once it is

reduced to the desired level the product can then be packaged for storage.

Unfortunately, merely reducing moisture content is not always sufficient.

Environmental conditions can play a role as well.

Proper moisture maintenance is also important according to the company

standard so that there is correct weight of packaged biscuits and to ensure

that specified number of biscuits goes into each packet. Thus moisture is an

important quality parameter.

Proper moisture content is essential for maintaining fresh, healthy foods. If

a food is too moist or too dry, it may not be suitable to eat and will not taste

as good as it would if it had the correct moisture content. Also the size and

shape of the biscuit is dependent on the moisture content of the biscuit.

A typical defect of biscuit is cracking or checking, as a result of the moisture

gradient in the product after baking.

PROCEDURE:

1)To study moisture variation in the process line, we collected samples

from the Dough end, Oven end and the Packaging end.
http://en.wikipedia.org/wiki/Waterhttp://en.wikipedia.org/wiki/Ovenhttp://en.wikipedia.org/wiki/Ovenhttp://en.wikipedia.org/wiki/Ovenhttp://en.wikipedia.org/wiki/Water


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2)First from the dough end, approximately 18 biscuit shaped doughs

are collected across the conveyor belt so that we can get samples

from working, non-working and the centre of the conveyor belt.

3)To mark the row from which we have collected from the dough end,

we place different shaped dough in that row. ( e.g. heart shapedwhich is different from the shape of all the other doughs). This is

done so that the row is easily identifiable and collection of sample in

the successive process becomes easier.

4)The sample thus collected is quickly put into plastic bags so as to

prevent moisture intake from the surrounding.

5)It is then taken to the laboratory for moisture check as quickly as

possible.

6)

Then from the oven end, approximately 18biscuits are collectedacross the conveyor belt so that we can get samples from the

working, non-working and centre of the conveyor belt.

7)But this time we have to careful that we collect the sample only from

the row which is before or after the row from which the doughs were

collected. The row is marked by the different shaped biscuit.

8)The biscuit sample is quickly put into plastic bags and the mouth is

tightly tied to prevent absorption of external moisture.

9)

It is brought to the lab and quickly placed in the dessicator and leftfor some time to cool.

10) The biscuits are then collected from the packaging end, across

the conveyor belt so that we can get samples from the working, non-

working and centre of the conveyor belt.

11) This time also we have to careful that we collect the sample

only from the row which is before or after the row from which the

doughs were collected. The row is marked by the different shaped

biscuit.12) The biscuit sample is quickly put into plastic bags and the

mouth is tightly tied to prevent absorption of external moisture.

13) It is brought to the lab and quickly placed in the dessicator and

left for some time to cool.

14) To determine the moisture from all the three process line we

followed the same procedure.

15) About 5 g of the sample was weighed in to a petri plate which

was previously weighted. Then it was dried in a hot air oven.


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16) Then the petri plate with the dried sample was covered

and was transferred to dessicator and weighed quickly as

possible as the dish was cooled.

17) The heating and weighing procedures was repeated until

successive weight did not differ by more than one milligram .Loss inweights were recorded.

FORMULA FOR MOISTURE DETERMINATION IS:

Moisture % = [(M1M2)*100]/M1M

M1= weight in gm of petriplate with sample initially

M2=weight in gm of petriplate with sample after drying

M = weight in gm of sample taken

OBSERVATIONS:

SAMPLE NAME: TIGER KRUNCH CHOCO CHIPS

DOUGH OVEN PACKAGING

ATE Working

side

Centre Non

Working

Side

Working

side

Centre Non

Working

Side

Working

Side

Centre Non

Working

Side

8/06 13.13 13.28 13.42 1.33 1.34 1.43 1.53 1.68 1.7

9/06 12.77 12.83 12.92 0.70 0.72 1.45 0.87 0.90 0.92

0/06 13.36 13.34 13.52 0.82 0.88 1.47 0.817 0.89 1.56

COMMENTS:

1)As we see from the chart the moisture content in the dough is directly

proportional to the final moisture content in the finished product.


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That is the reason the moisture content of the biscuit on 19/06/2012

is less, both at oven end and at packaging section.

2)Also ambient moisture content influences the uptake of moisture at

packaging end resulting in higher moisture content of finished

product.3)A temperature gradient is observed in the oven with the highest

temperature at the Working side and lowest in the Non-working side.

4)We see from the chart that moisture content in the dough end is

highest then at the packaging and then the oven end. This is because

there is a lot of moisture in the ingredients during mixing. After the

biscuits emerge from the oven it has the least moisture content as

most of it is evaporated due to the high heat in the oven. During the

journey of the biscuits from the oven end to the packaging sectionthrough the conveyor belt, it takes up moisture from the surrounding

environment and hence its moisture content rises slightly.

5)Again we see from the chart that there is a variation of moisture from

the working end to the non working end. The non working end

having the maximum moisture content, then the centre and finally

the working side. This phenomenon may occur due to non uniform

heating in the oven, not proper maintenance of temperature in oven,

malfunction of the heating tubes etc.6)Biscuit is a low moisture bakery product and its moisture content

varies widely, because of the variations in its thickness and weight

during forming and shaping.

AIM:TO DETERMINE THE VARIATION OF WEIGHT OF BISCUIT IN THE

PROCESS LINE

THEORY:

In law and commerce, including product packaging and nutrition

labeling, weightmeansmass.In science and engineering, the weightof an

object is theforce on the object due togravity.Weight is measured by
http://en.wikipedia.org/wiki/Masshttp://en.wikipedia.org/wiki/Forcehttp://en.wikipedia.org/wiki/Gravitationhttp://en.wikipedia.org/wiki/Gravitationhttp://en.wikipedia.org/wiki/Forcehttp://en.wikipedia.org/wiki/Mass


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Precision Weighing Scale, High Precision Laboratory Balance or Dhona

balance.

Weight loss is an index of moisture loss.

Weight is an important parameter which should be constant throughoutthe process line such that the net weight of each product is maintained. If

the weight of each biscuit is less than the specified limit then more number

of biscuits will go into the packet. Hence the company will run at a loss. If

the weight of each biscuit is more than the specified limit then less number

of biscuits will go into the packet and there will be customer complain and

the companys reputation will be at stake.

PROCEDURE:

1)To study weight variation in the process line, we collected samples

from the Dough end, Oven end and the Packaging end.

2)First from the dough end, approximately 18biscuit shaped doughs

are collected across the conveyor belt so that we can get samples

from working, non-working and the centre of the conveyor belt.

3)To mark the row from which we have collected from the dough end,

we place different shaped dough in that row. (E.g. heart shaped

which is different from the shape of all the other doughs). This is

done so that the row is easily identifiable and collection of sample in

the successive process becomes easier.

4)The sample thus collected is quickly put into plastic bags so as to

prevent moisture intake from the surrounding.

5)It is then taken to the laboratory for weight and moisture check as

quickly as possible.

6)Secondly from the oven end, approximately 18biscuits are collected

across the conveyor belt so that we can get samples from the

working, non-working and centre of the conveyor belt.

7)But this time we have to careful that we collect the sample only from

the row which is before or after the row from which the doughs were

collected. The row is marked by the different shaped biscuit.8)The biscuit sample is quickly put into plastic bags and the mouth is

tightly tied to prevent absorption of external moisture.


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9) It is brought to the lab and quickly placed in the dessicator and left

for some time for it to cool.

10) Thirdly from the packaging end, approximately 18biscuits are

collected across the conveyor belt so that we can get samples from

the working, non-working and centre of the conveyor belt.11) This time also we have to careful that we collect the sample

only from the row which is before or after the row from which the

doughs were collected. The row is marked by the different shaped

biscuit.

12) The biscuit sample is quickly put into plastic bags and the

mouth is tightly tied to prevent absorption of external moisture.

13) It is brought to the lab and quickly placed in the dessicator and

left for some time for it to cool.14) To determine the weight from all the three process line we

followed the same procedure.

15) Place the biscuits from the working end on the balance and

record the weight.

16) Place the biscuits from the centre on the balance and record

the weight.

17) Place the biscuits from the non-working end on the balance and

record the weight.

OBSERVATIONS:

SAMPLE NAME: TIGER KRUNCH CHOCO CHIPS

DOUGH OVEN PACKAGING

WORKING NON-

WORKING

WORKING NON-

WORKING

WORKING NON-

WORKING

18/06 6.43 6.52 5.71 5.56 5.59 5.36

6.54 6.55 5.74 5.63 5.62 5.61

19/06 6.82 6.80 5.89 5.85 5.85 5.79

6.66 6.72 5.91 5.90 5.77 6.00

6.53 6.74 5.80 5.85 5.85 5.94


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COMMENTS:

1)The weight is almost constant but sometimes there is a slight

variation from the working to the non working side.

2)The heat distribution is not uniform so there is a weight variation.

3)It also depends on the mode of heating.


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PREMIXING

MIXING

FORMING

BAKING

COOLING

PACKAGING

4 BISCUIT PRODUCTION

FLOWSHEET:

MIXING:

This is a process where all ingredients are put together in right proportion

for

dough formation. These ingredients are then fed into Mixers where mixing

is done and dough is prepared for molding. Major ingredients are flour, fat,

sugar and others as per the product.

There are 3 types of mixing:


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1. One stage mixing

2. Two stage mixing

3. Three stage mixing

One stage or All in Oneis type of mixing where all ingredients and water

are

added once. Mixing is allowed till satisfactory dough is prepared .Normally

this

type of mixing is used for hard Dough biscuits.

Two - Stage mixing:

Creaming: All ingredients are added with water and mixed 4-5 minutes

except for

flour.

2nd stage: Flour with chemicals are then mix with the creaming product to

form a

consistent dough.

Three- stage mixing:

Stage One: Fat, sugar with other ingredient like milk, chocolate, malt, honey

etc

are mixed and cream is prepared with portion of water.

Stage two: Salt, chemical and flavours with colors are mixed with water.

Stage three: Flour with water is then added to the prepared cream and

mixed till

satisfactory dough is prepared.

Four mixers in Britannia are:

1. 3SK Mixer

2. Prima New

3. Robinson Mixer

4. APV Mixer

3SK and Prima New Mixers are used for mixing short dough biscuits. E.g.:

Good Day, Tiger Crunch, Nice time.


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Robinson and APV Mixers are horizontal mixers. So these mixers are

suitable for hard and cracker variety dough biscuits, especially for the

sponge and dough process. E.g.: Cream Cracker, Marie Gold.

Mixing process has following characteristics which are monitored:

1. Mixing time: Normally any mixing could be achieved within 15-25

minutes.

It generally depends on mixing speed of mixer, flour characteristics

or temperatures required for dough.

2. Dough Temperatures: The temperature usually ranges between 35-

42C as per biscuit variety.

3.

Dough consistency: This is done manually by checking dough andstretching the dough it should not break neither should it be so

elastic. These methods are mastered by bakers by trial and error

method.

FORMING:

In the forming sections the dough is passed through several rolls to formsheets, these sheets are then converted into one uniform sheet of desired

thickness which is normally 5-6mm. Molders and cutters are used to cut


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sheet or convert dough into desired shape and size.

Stages in forming:1. Laminators: Dough after mixing is placed into laminators hoppers

with some mechanical /pneumatic tilting.

2. Gauge roll stands or Conveyer belts: Reduction in sheet is achieved

through numerous gauge roll stands. Generally three or four stand gauge

rolls are used. Reduction are achieved in stages as not to create too much

stress on the sheet , webs are provided in between for relaxation even an

additional web is provided prior to cutter to release stress from dough

sheet. Best results are achieved through four stand gauge rolls. These gauge

roll are of different diameters depending upon the plant capacity. Speed is

set as per plant and cutter rpm. Gauge roll speed has to be increased in

every stand so as to maintain the flow of sheets.

3. Dough sheet conditioning: Dough sheet conditioning is done as per the

ambient conditions in the plant. The different methods used are:

Steam spray - to moist the web surface

Blower: to dry the dough surface.

Flour dusting: to dry the wet surface of the dough.

4. Toppings: Toppings are done through mechanical, vibratory or sprays.The toppings could be milk, salt,

sugar or cashew, pista bits.

5. Metal Detector: It is placed prior to cutters and molders for any damage

to the molding unit.

6. Rotary cutter: Rotary cutter consists of cups which are attached to the

cutter shell. This shell is then fixed to the shaft and drive mechanism.

Knives are provided at these molders to scrap through the dough so thatwe get flat and uniform biscuits.

7. Molding Roller: It is applied for short dough. The dough is prepared inlumps these are then fed to die roll through either reciprocating conveyor

to the hopper or a rotary conveyor which allows these dough crumbs to

spread uniformly on the die roller surface. These die roller have dies

engraved into it. Dough pieces are then released by feed roller which

pushes the dough into the dies.


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BAKING:

Wet dough pieces of desired weight and shape are then passed on tooven band through swivel panner web. Ovens are of different types

classified into following categories:

a. Type of heating: Heating is done by conduction, convection and

radiation. No direct heating is used.

b. Type of fuel: Fuels generally used are coal gas and diesel.

c. Type of design: Cyclotherm heating system and turbulence system

d. Width of oven band: Oven band transports the product through the

oven. It is supported by mechanisms at the feed end and the deliveryend.

e. Number of zones: 5-6 zones are usually used.

BAKING CHAMBER:

The baking chamber is classified into 6 zones. The first 2 zones are the

rising zones which work on indirect convection heating. Each zone is 6.3

metres long. The next 4 zones are baking and colouring zones, where

cyclotherm heating takes place. The zones are respectively 8.4, 12.6, 14.6

and 16.8 metres long. Air turbulence can be introduced to zones 3, 4, 5 and

6. Each zone has a control panel and a set of dampers. The baking

temperature and atmosphere can be controlled. Each zone of the oven is

heated independently. This enables the heat applied to the product to be

different in each zone, so that the following stages of the biscuit can be

controlled:

1. Development

2. Moisture removal

3. Colouring

Within each zone the ratio of top to bottom heat can be controlled. This

gives further heat control of the heat applied to the product at each stage of

the baking process. Top heat is applied to the top of the oven band. Bottom

heat is applied to the underside of the oven band. Zone 1 will therefore be

set with low % top heat and high % bottom heat. At the end of the oven the

colour of the biscuit is being develop, which requires high top heat. Zone 6

will be set with a % top heat, and a low % bottom heat. Five flame

impingement burners are fitted at the feed and extension to pre-heat the

oven band. Each impingement burner is rated at 27,720kcal/hr.


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COOLING:

Cooling process is as important as any other process. When biscuits come

out from the oven, the temperature of biscuits are around 70-95C. These

biscuit can be cooled by letting it travel for distance of 1.5 times of baking

time. So when the length of oven is 200 ft then cooling conveyor length

would be approx 300 350ft. In some places forced cooling is also done

due to space constrain or for special features .Cooling brings temperatures

to room temperature for handling of biscuit for packaging.

DIFFERENT PARAMETERS CHECKED DURING BISCUIT

PROCESSING:1. Dough consistency

2. Metal detector

3. Dough weight

4. Shape of dough pieces

5. Sprinkling (Sugar/ Cashew; dryness; granularity; uniformity)

6. Band spacing

7.

Baking profile8. Baking time

9. Biscuit colour

PARAMETERS CHECKED AT OVEN END:1. Baking profile

2.

Colour

3. Size

4. Shape

5. Surface finish

6. Gauge weight


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GRAPH SHOWING CHANGES DURING BAKING:

Different biscuits and their processing in Britannia:

CREAM CRACKER: It is a fermented or cracker type biscuit. The processflow diagram for Cream Cracker is as follows:

Flour sieving and

weighing; sol

bake, malt and

sugar added

Sponge

Dough

Pre aration Cutting


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There are 3 stages in mixing of Cream Cracker biscuit:

1. Sponge formation: It

is done at a temperature of 25-26.6 Celsius for around 5 minutes. 3

minutes of fast mixing is followed by 1 minute of slow mixing.

Standing time for sponge is 1hrs and 30 minutes.

2.

Dough formation: Itis done at 33.3-36 degree Celsius for 10 minutes. Standing time is 1

hours and 30 minutes.

3. Final dough: The

dough obtained after keeping for 1.5 hours is called the final dough.

Ingredients:

For sponge preparation:

1. Wheat flour: 450kg

2. Gluten: 2.5kg

3. Yeast: 5kg

4. Water: 50 litres

5. Malt: 675gm

6. Dusting sugar: 7kg

Layering

Sheeting

Cutting

Transferring

Baking

Cooling and

transferrin

Packaging


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For dough preparation:

1. Fat (generally palm

oil): 40kg

2.

Water: 20 litres

3. Wheat flour: 450kg

4. Yeast: 1kg

5. Salt: 4kg 50gm

6. Solbake: 7kg

7. Spray

For Spray preparation:

1. FCCM: 10kg

2. Water: 50kg

Specific gravity: 1.035-1.040

Standard diameter is 56-57mm.

Temperature variation in different zones of the oven:(Baking time:

5.61minutes)

Zone 1

(10C)

Zone 2

(10C

)

Zone 3

(10C)

Zone 4

(10C)

Zone 5

(10C)

Zone 6

(10C)

225 C 330 C 340 C 295

C

295C 220C

MARIE GOLD: Marie Gold is a hard dough biscuit. It is prepared in the

same procedure as Cream cracker but fermentation is not carried out.

Spray Preparation:

1. FCCM: 10kg

2. Water: 37.5kg


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3. Caramel: 100ml

4. EMGC: 50ml

5. Invert syrup: 3.5kg

Specific Gravity: 1.055-1.060

Standard diameter is 62.5mm.

Average weight of 37 biscuits is 201gm.

Temperature variation in different zones of the oven:(Baking time:

5.51minutes)

Zone 1

(10C)

Zone 2

(10C)

Zone 3

(10C)

Zone 4

(10C)

Zone 5

(10C)

Zone 6

(10C)

190 C 280 C 300 C 285 C 285

270C

GOOD DAY BUTTERBITES: It is a soft dough biscuit.

There are 2 stages of mixing:

1. Creaming for 4-8mins

2. Formation of dough

(3-8 minutes)

Dough temperature is 30-35C.

The ingredients required for the preparation of dough: (per 2.25sack)

1. Flour:285.75kg

2. Lawn Sugar: 108kg

3.

Palm oil:86.4kg

4. Butter: 22.5kg


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5. Lecithin: 0.78kg

6. GMS Paste: 4.05kg

7. SMP (dry): 9kg

8.

Whey powder: 2.25kg

9. Salt: 2.25kg

10. Soda: 0.675kg

11. M/Sugar: 1.13kg

12. ESS/Butter F: 2203: 112.5ml

13.

Flavour BS: 337.5ml

14. Flavour MM: 56.25ml

All the ingredients are mixed together and creaming is done. Finally

flour is added to prepare the final dough.

Temperature variation in different zones of the oven: (Baking time:

5.48minutes)

Zone 1

(10F)

Zone 2

(40F)

Zone 3

(10F)

Zone 4

(10F)

Zone 5

(10F)

Zone 6

(10F)

400F 465 F 490 F 440 F 435 F 160 F

Standard diameter of Good Day is 52mm.

Weight of 25 biscuits is 231gm.

TIGER KRUNCH CHOCOCHIPS:It is a soft dough biscuit. Mixing is

done in 2 steps:

1. Creaming: Creaming is

done with biscuit dust for 8 minutes.

2.

Final Dough: Finally

the flour is added and mixed for 5 minutes (3 minutes high


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speed followed by 2 minutes slow speed) to prepare the final

dough.

Ingredients for the preparation of dough: (Per 2.25sack)

1.

Wheat flour: 285.75kg

2. Lawn sugar: 96.75kg

3. Palm oil: 88.31kg

4. Lecithin: 0.9kg

5. Liquid glucose:

11.25kg

6. Solbake paste: 5.063kg

7. Sweetened condensed

milk: 4.5kg

8. Salt: 3.38kg

9. Cocoa powder: 9kg

10. Chocochips: 45kg

11. Soda: 1.35kg

12. M/Sugar: 6.75kg

13. Dicalcium phosphate: 0.27kg

14. Ferrous fumumarate: 110.25gm

15. Folic acid: 0.27gm

16. D.S Caramel: 0.74kg

17. Flavour chocolate: 0.608kg

18. Ammonium

bicarbonate: As per required

At first Palm oil is added followed by lawn sugar. Then lecithin and Solbake

paste are added. Then sweetened condensed milk and other flavouringsubstances are added. Finally flour is added with the Chocochips.


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Temperature variation in different zones of the oven: (Baking time:

5.50minutes)

Zone 1(10F)

Zone 2(40F)

Zone 3(10F)

Zone 4(10F)

Zone 5(10F)

Zone 6(10F)

390F 450 F 490 F 445 F 420 F 190 F

Standard weight for 20 biscuits is 113gm.

TROUBLESHOOTINGS FOR THE DEFECTIVE BISCUITS AT THE

OVEN END:

1.

When baking is not

proper the temperatures at different zones are adjusted.

2. When colour is light or

dark compared to the original colour, the temperature of 5thand 6th

zone of baking oven is adjusted.

3. Shape and size is

adjusted by final gauge roller. The oven steam damper, which ispresent in zone 2 and 3 of baking oven are also adjusted.

4. Surface finish is made

proper by preparing a proper spray and varying the ingredients of

the dough and flour dust.

5. If excess water is used

the biscuit becomes soft, elongated and curling. Thus proper quantity

of water is used.

6. When the biscuit does

not meet any of the parameters, it is either rejected or recycled.

5 BISCUIT PACKAGING

Introduction


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Packagingis an important part of processing & distributing foods.

Whereas preservation is the major role of packaging, there are several

other functions of packaging.

1) Packaging must protect from any mechanical damage to the product

2) Packaging must have all information about the product for

consumers. Most of the countries have laws for food packaging

3) Packaging should help consumer carry, store and handle easily.

Features like tear tape may be used.

4) Colors and layout of product packaging are tools for advertisement

for manufacturers.

5) Maintain shelf life of products.

6) Packaging acts as barriers to heat, moisture, aroma etc.

Environmental factors such as oxygen, water vapor will spoil foods if they

are allowed to enter packages freely.

7) Packaging must protect against a variety of assaults including

chemical attack and contamination from biological vectors including

microorganisms, insects and rodents.

Generally packaging materials can be divided into two types:-

Primary packaging materials

Secondary packaging materials

Primary Packaging Materials- Primary packaging materials are thepackaging materials which are in direct contact with food (in this case

biscuits). Primary packaging materials must be non toxic, compatible with

the biscuits and should cause no color, flavor or other chemical reactions.

These packaging materials are supplied as rolls to the product

manufacturers as it is easier to put roll into packing machine.

Laminatesare primary packaging materials.


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Secondary Packaging Materials-Secondary packaging materials are

those which are not in direct contact with the food (in this case biscuits).

Incase of packaging of biscuits Card Board Box (CBB)is used as secondary

packaging materials. CBB are made of Kraft papers generally. Secondary

packaging materials must protect the primary packages from damageduring transportation and storage. It also prevents dirt and contaminants

from soiling the primary packages.

Britannia biscuits are available in Family Pack and Pillow Pack.

Process flow sheet of packaging of biscuits:-

Metal Detector

Stackers

Feeding Chute

Horizontal Flow Wrap

(Horizontal Form, Fill and Seal

machine)

Packing in CBB

Baking Oven

Cooling Conveyor


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Baking oven to cooling conveyor-Biscuits that come out from the

baking oven are then transferred to the cooling conveyor for cooling of hot

biscuits. Cooling brings temperature of the biscuits to room temperature

for handling of biscuits for packaging. Length of the cooling conveyor is

1.5times the length of the oven.

Metal Detector-Biscuits are next passed through metal detector which

will detect presence of both ferrous and non-ferrous particles. If metal is

detected, then the biscuits in that zone are discarded.

Stackers-In the stacker a brush is present which constantly rotates and

allows only a single biscuit to pass to each channel. Main aim of the stacker

is to achieve proper distribution of biscuits into packing machines.

Feeding Chute-From the stacker the biscuits are manually put in the

feeding chute. Feeding chute carries the biscuits to the horizontal form-fill-

seal machine.

Horizontal Flow Wrap-


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The machine is designed with automatic feeding arrangement to precisely

take the required stack length with the help of inline pusher and transfer

the biscuits smoothly into the main feeding conveyor with the help of cross

pusher. During this process, nylon lugs carry the biscuits with wrapping

material to the main wrapping unit through the easy adjustable forming

box for different varieties, through the pair of hot body sealing rollers forbody seal. The final end sealing and cutting is done by the rotating hot

cutter.

Packing in CBB-Finally the biscuits are manually packed in Card BoardBoxes and tapped. While packing in each card board box 10 liners are used.

Paper liners are used for products in CBBs to protect them from damages

during shipments .The liners are kept between the packets to provideadded protection against excessive pressure on them which may results

breaking of biscuits.

Defects of Packaging:-

1>Off centre packet2>Off coding packet

3>Loose packet

4>

Weak seal packet5>Less weight biscuit packet

6>Leaky packet

Precautions Taken During packaging:-

1> the biscuits should be cooled properly before packing for ease of

handling during packaging and if hot biscuits are packed then moisture will

condense inside the packet affecting the shelf life.

2> the metal detector should function properly or any foreign particle may

enter the stacker.

3> the operators hand should be kept clean as the biscuits are manually

put in the feeding chute.

4> in the horizontal flow wrap heating and sealing of the packed biscuits

should be maintained at a particular temperature or biscuits packets couldnot be formed.


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5> the fingers should be kept out of the horizontal flow wrap machine or

any danger might occur.

6>Containers should not be filled either too loosely or too tightly for

best results. Loose products may vibrate against others and cause

bruising, while over packing results in compression bruising.

6 DESPATCH

Process Flow Sheet of S&F (Stock and Forwarding):-

Packaging

section

Stock as

per plan

Depot


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Precautions:-

1)The trucks are inspected. The platform should be uniform, chassis

should be smooth, should be free from odor and there should be

tarpaulin spread.

2)

The CBBs in the stock are not kept on the ground so as to ensure thatis no damage from rodents, insects and water on the floor.

3)Most work is done by conveyors and machines so as to reduce

handling to ensure low labor cost, damage of biscuits and saving of

time.

4)CBBs should be placed in the truck in a slanted manner.

5)For covering the biscuits after loading in the truck, tarpaulin sheet is

spread and tied using ropes. These ropes are passed over the angles

so as to prevent damage of CBBs and hence the biscuits.

Authorized

wholesaler

Retailer

Customer


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7 CONCLUSION

Finally completing 21 days summer training in Britannia Industries Limited

we are highly benefited. Before this training we used to have a limited

theoretical knowledge about biscuit manufacturing. But through this

training we have acquired practical knowledge about the biscuitmanufacturing. It became easy for us to understand all the processes

clearly when we observed them occurring in front of us and when we are

allowed to perform various tests with our own hands. We are now able to

relate our theoretical knowledge with the practical knowledge that we have

gained. We are guided to each and every section of this factory and are

explained every processes clearly by various officers to whom we are very

thankful to. Friendly nature of all the officers and other staff members in

this factory has helped us to interact with them to clear our doubts.Through this training we have also been benefited for our future when we

ourselves will work in an industry. Our overall training experience in

Britannia Industries limited is memorable.


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Date post:	03-Jun-2018
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Britania Report

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