BYBYASHAASHAAARTI NIMANIAARTI NIMANIMINACSHIMINACSHILALITHA SUDHALALITHA SUDHASANTANA PRIYADARSHNISANTANA PRIYADARSHNISANGAMITRASANGAMITRASAHITYASAHITYAASHNAASHNA
INTRODUCTION
• We undertook this internship programmed training at Mega foods Pvt.Ltd.
• The training was for a period of 4 weeks.• We were groomed to accept various
challenges of industry and learnt to keep up the time limit. This enabled us to correlate theory and practical.
INFRASTRUCTURE• The factory is located on a site of about 26500 square ft.• The unit is located in a well-developed industrial estate which
is close to the city.• The man power employed include professionally qualified
people heading each department.• Reverse osmosis plant is also provided for the safe usage of
water.
Mission statement “TO PRODUCE QUALITY FOOD PRODUCTS THAT ADD
VALUE TO OUR CONSUMER,BUYERS,DEALERS AND EMPLOYEES AND THEREBY BECOME THE MOST
REPUTED AND PROFITABLE COMPANY”
PROMOTERS
• THE CHIEF PROMOTER OF THIS COMPANY IS MR.AMIT C VAISHNAV, A MECHANICAL ENGINEER AND A MEMBER OF FOOD SCIENTISTS AND TECHNOLOGISTS(MYSORE)
PRODUCTS
• JAMS• CHIILY SAUCES• SOYA SAUCE• READY TO EAT PRODUCTS• SQUASH• FRUIT SYRUP• TOMATO SAUCE/KETCHUP
LAB ANALYSIS• Lab analysis consists of the various tests done in order to
prepare a stable and consistent food product.
• There are various apparatus that are used for eg:pH meter ,etc.
• The following tests are done in this food industry:
1)BRIX TEST 2)ACIDITY OF PULP 3)pH OF PULP/JUICE
This test is done in order to asses the amount of dissolved salts present inthe given fruit extract.
The instrument used to perform this test is knownas the refractometer.
The refractometer used for juices ranges between 0-50% and that of jams is 40-85%.
Acidity test is done in order to determine the amount of acid added to the fruit juice or pulp and thereby determine the amount of extra acid that has to added.
The calculation of acidity can be done in 2 ways:-
1)Acid-base titration
2)pH method
The pH method is done with a pH meter.
The pH is done to check and hence maintain the acidity of the given fruit pulp or juice.
COMPANY HYGIENEOne of the most essential factors to be maintained in a food
industry is hygiene. At Mega foods the following measures are followed:-
1)On entering the production area one must disinfect their hands using a sanitizer and the workers should wash their legs.
2)People who are associated with preparing the food products should not wear footwear.
3)All workers are to wear lab coats and also cover their head with a head cap to prevent hair from falling into anything.
4)All machines should be washed and cleaned before use.
Puree/ pulp preparation for jams and sauces
Receipt of fruits/vegetables
Incoming inspection
Storage
Send back to supplier
100% segregation
fruit?/vegetables washing
Fruit cutting/preparation Processing Cleaned cans
Pulp storage in cansA
Ok
ALAB analysis, menu generationand issue of RM as batch cardTransfer ingredients to kettle,Process and finish product
Lab inspection Move to reprocess area
Transfer to SS vessel scrap
Fitting operation
Seating
Labeling
Packing, storage and dispatch
LAB inspection
Stored for reprocess
B
C
D
E
Not Ok
Not Ok
MANUFACTURING PROCESS OF JAM
Tested pulp( brix test and acidity) is added to kettle and boiled
Addition of sugar and pectin with continuous stirring and boiling
Addition of citric acid
LAB test for final standards and end test
Addition of coloring agents and flavoring agents.Sent for filling and packing
All jams are prepared in similar manner with slight variations.
MANUFACTURING OF DIET FRUIT JAM
Tested pulp (brix test and acidity)Is added to kettle and boiled.
Sorbitol+ diet+ pectin+ calcium chloride+ aspartame
Addition of citric acid
LAB test for final standards and end test
Addition of coloring agent and flavoring agent.Sent for filling and packing.
DIET FRUIT JAM
JAMS• Mixed fruit jam• Pineapple jam• Grape jam• Mango jam• Strawberry jam• Raspberry jam
TESTS CONDUCTED TO CHECK JAMS READINESS
• Sheet test
• Plate test
• Cut test
INGREDIENTS Orange juice (Unpeeled orange is cut into four pieces and boiled in water
and as soon as the juice oozes into the water, extract is filtered), sodium benzoate, citric acid, sugar, pectin, coloring and flavoring agent
MANUFACTURE OF ORANGE MARMALADE boiled
tested for acidity and Brix
Orange juice+ sodium benzoate Add sugar and pectin
Add citric acidAdd coloring and flavoring agent
Sent for filling and packing
Sauce / ketchups
• They are mainly manufactured according to demand
• They are made from puree or paste
• The sauce manufactured is Tomato sauce Tomato ketchup Chilly sauce Soya sauce
Ingredients Tomato puree (cooked without water and passed through a pulpier), sugar, salt, sodium
benzoate, sodium saccharine, red chilly powder, turmeric powder, cinnamon oil, clove oil, gum and water
Manufacture of tomato puree
tomato puree+ sodium benzoate+Red chilly pdr + turmeric pdr +
1 part of sugar
Add sugar &gumWith continuous
stirring
Put in colloid mill
Add acetic acid, corn flour,Cinnamon oil, clove oil
Sent for fillingAnd packing
tested for acidity ,brix and salt boiled
Tomato ketchup
Ingredients
Tomato puree (cooked without water and passed through a pulpier), sugar, salt, sodium benzoate, ginger-garlic paste, onion, red chilly powder, ginger oil, cinnamon oil, corn flour, gum and water.
Manufacture of tomato ketchup
Tomato puree+ ginger garlic paste+ sodium benzoate+
Onion+ red chilly pdr
Heating followed by addition Of corn flour
Add cinnamon oil, sugar,Ginger oil
Sent for filling andpacking
passed through colloid mill
CHILY SAUCE
INGREDIENTS Chilly paste, potato paste, water, gum, mustard solution, salt, jaggery, ginger-garlic
paste, sodium benzoate, turmeric, MSG.
Manufacture of chilly sauce
Add potato paste+ mustard sol
Add jaggery+ salt+ sodiumBenzoate+ turmeric pdr+
MSG
Sent for fillingAnd
packingFinal lab test
Chilly paste
tested for salt , acidity, brix
Soya sauce
INGREDIENTS Soya extract (Soya beans are cleaned, socked and cooked under pressure till they
become soft. It is then crushed and it is sprayed in tray. It is inoculated with species of mould-Aspergillus Niger and incubated in a sterile room at 37 degree Celsius for 76-96 hours and left for 6 months for fermentation) salt, gum, water, jaggery, caramel, color mix, ginger-garlic paste, sodium benzoate and corn flour.
Manufacture of Soya sauce
Soya extract+ jaggery sol+ salt+ caramel+ MSG+
Sodium benzoateBoiled and checked
For brix
Sent for fillingAnd packing
INGREDIENTS
• Fruit pulp • Sugar• Citric acid• Sodium benzoate• HS gum
• Potassium sorbate• Sodium citrate• Water• Color mix• Flavor
Addition of coloring and flavoring agent
INGREDIENTS
• Fruit pulp• Aspartame• Sorbitol• Citric acid• HS Gum
• Potassium sorbate• Sodium citrate• Water• Color mix• flavor
•Sodium benzoate
Addition of coloring and flavoring agent
Pod type of capsicum, medium to large size chili
pepper
PREPARED SYNTHETICALLY
WASHING
the bottles are soaked in cold water
Soak in soap water
washed in ordinary water then with hot water mixed with sodium benzoate.
PNEUMATIC FILLING
SHRINK TUNNEL
BOTTLE STERILIZER
POUCH PACKING
FILLING
the filling machine is first washed with 0.01% sodium benzoate + hot water
the bottles are filled
they are sealed with zinc seals and closed with suitable caps
allowed to cool
counted and recorded
STEAMING
after washing they are sent to bottle sterilizer machine.
flow of water
them steamed to sterilize bottles.
PACKING
wiped
labels
shrink cover and sent through the shrink tunnel
carton box
100g, 200g, 500g and 4kg containers
IN FACTORY