biscuit manufacturing

PPT file

Presented by:- SARIKA DEVI SUMIT SAHGAL SHOBHA

Company Profile
Britannia Industries Limited(BIL)

In 1892, with an initial investment of 295 in Kolkata.

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.

Leadership position in Indian bakery market with 124 billion.

Market share of ~38% in the industry.

It has an annual production capacity of 433,000 tonnes and has got 600,000 outlets across India.

In International markets over 30 Countries and a number two brand in the UAE and Oman.

BRIEF ABOUT UTC

Production trail started on 1st April 2005 in Rudrapur.

Total plotted area of approximately 20 acres.

the purpose of production of biscuits as this area is free from all types of taxes.

New concept like 5S

SEIRI: Organization,

SEITON: Neatness,

SEISO: Cleanliness,

SEIKETSO: Standardization,

SHITSUKE: Discipline

The Company is perusing for ISO 14001 certificate and it is ISO 22000 certified.

This unit enjoys the excise and income tax benefit from Uttarakhand government.

PRODUCTS OVERVIEW

GLUCOSE BISCUITS BRITANNIA TIGER

MARIE BISCUITS BRITANNIA MARIEGOLD, NUTRICHOICE

COOKIES GOOD DAY BUTTER, GOOD DAY CASHEW, GOOD DAY PISTA BADAM

CRACKERS 50-50 CHASKA-MASKA

CREM BISCUITS TREAT(orange, pineapple, strawberry, fruit)

BISCUITS

MACHINES & AREA

Boiler

Hot water generator

Chocolate melting tank

Butter melting tank

Load cell (Butter)

Lecithin, Solbake, GMS paste preparation tank

SMP Solution tank

Filter for invert syrup

Invert syrup solution tank

Sugar syrup solution tank

Sieves

Silo

Flour tank

Sugar grinder (Manual)

Automatic sugar grinder tank

Cold store

Flour sampling sieve

Cocoa powder

Weighing balance (Heavy)

Atta sifter sieve

Bran sifter sieve

Lift for uplifting materials.

Chocochip store

Butter, HVO store area.

Cold store for nuts.

Cold store for flavor

Sugar storage area.

Flour storage area.

Laboratory

General store office

Wash room.

Shelf life room

INGREDIENTS

WHEAT FLOURWATERSUGARFAT &OILSALTFLAVOURMILK & MILK PRODUCTLEAVNING AGENTEMULSIFIERCOLOURWheat Flour

Principal ingredient in Bakery products.

Unique ability to form Gluten.

Gluten is made of Gliadin & Glutenin (Insoluble Proteins).

Soluble proteins present in wheat flour are Albumin & Globulin.

Gluten is elasticlike and forms matrix.

Gluten forms only on mixing with water.

Gliadin contributes to elasticity & Glutenin imparts strength (Resistance).

Both quantity & Quality of gluten are important in assessing the strength of flour.

WATER

2nd major ingredient in Bakery products.

Hydration of proteins.

Acts as a dispersion medium for sugar & other chemicals.

The consistency of dough largely depends on water.

An excellent leavening agent.

Medium hard water is preferred for most of the Bakery products, as some of the mineral salts (like Calcium salts) have a strengthening effect on gluten and some (like Ammonium salts) serve as yeast foods.

FATS & OILS

Act as lubricants.

Tenderizing agent.

Provides texture/structure to the product.

Act as aerating agents.

Eating quality (Palatability).

Moisture-barrier in finished products.

SUGAR

Particle size of sugar greatly affects baking properties.

Gluten Development.

Leavening.

Creaming.

Gelatinization.

Caramelization.

SALT

Preservative.

Texture aid.

Binder.

Fermentation Control.

Flavor Enhancer.

MILK & MILK PRODUCTS

Flavor and taste contribution.

To enhance crust color and bloom.

To improve tenderness of the product.

To improve the texture without altering the symmetry and crumb color.

To reduce the greasy feeling in sandwich creams.

As an alternate to eggs (use of whey protein concentrates).

FLAVOURS

Taste enhancer

Dispersibilty in water or fat as per requirement

Expression/Stability at the product pH.

Compatibility to the product as the expression of flavor generally varies with the fat content in the product.

Masking any undesirable odour from the product.

Closeness to the natural product envisaged.

COLOURS

To provide identity to the food product.

To provide variety to the consumer.

To correct the natural variations in the color of the food.

To enhance the natural color but at levels lower than that usually attached to the given food.

To protect food products, flavors and vitamins that can be affected by exposure to light.

EMULSIFIERS

Starch complexing (anti-staling)

Protein complexing (Dough strengthening)

Viscosity modification

Foaming and aeration

Texture modification

Lubrication

Crystal modification

As Wetting agents & solubilisers.

Suspension & dispersion.

LEAVNING AGENT

Rise the volume of dough

Baking powder contains baking soda and the right amount of acid to react with it.

Batters made with double acting baking powder rise twice;

once when dry and moist ingredients are mixed together, and again when the product is baked.

1-S.B.C.(Sodium bicarbonate)

2-A.B.C.(Ammonium bicarbonate)

Above 70 C, it gradually decomposes into sodium carbonate, water and carbon dioxide. The conversion is fast at 250 C 2NaHCO3 Na2CO3 + H2O + CO2Leavening agents where in application low final moisture content is reached in baked products such as cookies and crackers. NH4HCO3 NH3 + H2O + CO21-S.B.C.(Sodium bicarbonate) 2-A.B.C.(Ammonium bicarbonate) 1) Wheat flour

2) Palm oil:

% Moisture: 14 (max.)

% Total ash: 0.8 (max.)

% Acid insoluble ash: 0.05 (max.)

% Alcoholic acidity: 0.12 (max.)

% Gluten on dry basis: 7.5 (min.)

Germ oil acidity (as oleic): 15 (max.)

Granularity : 85 mesh sieve ( 99% should pass through )

Sedimentation value : 17 to 30

Taste and colour : should be characteristic

Extraneous matter : should be absent

Origin : should be of vegetable origin

% FFA -0.10 max. (as oleic acid )

% Moisture: 0.10 (max.)

Peroxide value: 1.5 (max.)

Refractive index : 1.4491- 1.4552

Saponification value : 195 205

Unsaponifiablematter: 1.2 %( max.)

Iodine value : 45 56

Melting point: 37 C (max.)

3) Sugar:

% Moisture : 0.1

% Total sugar : 99.5

SO2 : 70.0ppm

ACCEPTANCE CRITERIA FOR INGREDIENTS

BISCUITS MANUFACTURING

Material receivingPremixing CreamingMixingMoulding

PREMIXING

BISCUITS GRINDING MACHINE

NUT SHORTNING ROOM

INVERT SYRUP PREPARATION

C:\Users\trikx005.KRFT\Desktop\Pic- 9th dec\20131211_121255.jpgSIEVE

LECITHIN PASTE PREPARATION

1 Kg Lecithin + 3 Kg HVO

Mixture dumped to Lecithin Paste Preparation Tank

Steam from boiler

Mixture melts and ready to be used BUTTER PREPARATION

Butter melting tankFilter Load cell Storage tankMixture

SKIM MILK POWDER(SMP) PREPARATION

75 Kg of SMP

150 Kg water

Solution prepared & ready to be used in the mixer MIXING

Then it is mixed with other ingredients for further 2 minutes. SIGMA ARM MIXTURETo entrap air and to mix all ingredients.

It involves mixing of fat, sugar, flavour except flour, creamed for 8-12 minutes.

CREAMING

CONTINOUS MIXTURE

Mixing time is around 2 min. Benefits of Continuous Mixing

Simplifies the mixing process

Disperses ingredients consistently

Simplifies dough feed equipment

Provides tight control over the mixing process

Is safer , more sanitary and can be operated with less labour and energy than batch mixing

Is easy to sanitize, maintain, clean and inspect due to the clamshell design

No dough contamination because the dough is never exposed to the environment

Is easy to operate due to the user friendly controls

Controls ingredient metering to the mixer so its precise and uninterrupted.

Dough is prepare

C:\Users\SONY\Desktop\ppt\20140623_162041.jpgMOULDING

A-Forcing roller C-Extraction roller E-Extraction web H-Hopper B-Moulding roller D-Scraper(Knife) F-Cleaning scrapper CUTTING

C:\Users\SONY\Desktop\ppt\20140619_100828.jpgBAKING

The zones are classified as: There are 7 independent zones in all three plants. These are

a) Proofing zone: zone 1 & 2 (Structure is set here)

b) Puffing zone: zone 3 & 4 (Product get oven spring)

c) Baking zone: zone 5 & 6 (Moisture removal of product) d) Colouring zone: zone 6 & 7 (Millard & Caramlization)The Physical changes

The Chemical changes

Large reduction in product density.

Development of an open porous or flaky structure.

Change of shape associated with shrinkage or spread and increase in thickness.

Reduction in moisture level, to between 1-4%.

Change in surface coloration (reflectance).

1. Gas formation

2. Starch gelatinization

3. Protein denaturation

4. Caramelization of sugar

5. Dextrinisation of starch

C:\Users\Suneel Admin\Desktop\5_1.jpgC:\Users\SONY\Desktop\ppt\20140626_103920.jpg

COOLING

These baked biscuits are then passed on to cooling conveyors for natural cooling prior to packaging. The temperatures are brought down to room temperatures. It should between 35- 40C. cooling-conveyorINSPECTION OF BISCUITS

STACKING

C:\Users\SONY\Documents\IMG-20141011-WA0003.jpgPACKAGING

30 to 150 Packing per minute.

Auto feeder Ferrari Machines.

These packs are then put into secondary packaging like cartons to be transported to retailers. Packing machine can be selected as per the plant capacities and nature of packing. C:\Users\SONY\Documents\IMG-20141011-WA0002.jpgPacking Materials

Primary Packaging Materials:

BOPP films(Biaxially Oriented Polypropylene)

Aluminium Foils

Plastic Trays

Secondary Packaging Materials:

PET jars (Polyethylene terephthalate)

ATC (Air traffic control) boxes

CBB (Corrugated Board Boxes)

Batch no.

For Good Day (CHOCO-CHIP)

BISCUITS NET WEIGHT75g

MRP. 20.00

(incl. of all taxes)

PKD.30/07/15

LOT No.B071595

MACHINE CODE:03C01

BEST BEFORE SIX MONTH FROM PACKAGING

Metal detector

The "Balanced Coil" SystemExcellence with X-rayELECTRICITY SUPPLY

The transformer then converts the 11 KVA supply to 33 KV.

Volt remains almost constant to 33 KV but ampere fluctuates with variation in power consumption during production and other factors. It is generally of 25K amp.

There are 4 sets of A.C Diesel generators assemble for emergency purpose. Three is of 625 KVA and one is of 500 KVA.

SHEETING

HOW OVEN WORKS ?

OVEN

FLOUR RECIVING

Fuel

CNG, Thermofluid oil fuel used by Britannia industries limited.

Export

BIL Rudrapur export 60 tonnes of biscuits per month to Singapore, USA, Kuwait, Ghana, Oman, Saudi Arabia, Bahrain, Seychelles etc.

We work with UTC team

Officers, SGR & Manager 99

Total Manpower (Workers) 2200

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biscuit manufacturing

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