INNOVATIVE BISCUITS PVT.LTD. - Food Science Universe Innovative Biscuits PVT... · At Innovative...
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1 INNOVATIVE BISCUITS PVT.LTD. Submitted to Dr Ghulam Mueen-Ud-Din Submitted by Hafiza Rahma Saman Roll No. 21 BS (Hons) Food Science & Technology Semester 8 th (R) INSTITUTE OF FOOD SCIENCE & NUTRITION UNIVERSITY OF SARGODHA, SARGODHA 2015
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Transcript of INNOVATIVE BISCUITS PVT.LTD. - Food Science Universe Innovative Biscuits PVT... · At Innovative...
1
INNOVATIVE BISCUITS PVT.LTD. Submitted to
Dr Ghulam Mueen-Ud-Din
Submitted by
Hafiza Rahma Saman
Roll No. 21
BS (Hons) Food Science & Technology
Semester 8th (R)
INSTITUTE OF FOOD SCIENCE & NUTRITION
UNIVERSITY OF SARGODHA, SARGODHA
2015
2
ACKNOWLEDGMENTS
First I avail this opportunity to bow my head before my ALLAH Almighty in humility who
given me wisdom and perseverance for completing this period of internship.
I am heartily thankful to my knowledge Bank teachers Dr Ghulam Mueen-Ud-Din and
Dr.Tahir Mehmoood Qureshi whose constant guidance and support enabled me to develop an
understanding of the subject which ultimately helped me in making of this report and to all the
teachers who guided me through the whole process of my internship.
At Innovative Biscuits Pvt. Ltd I would like thank
Mr. Aamir Sheikh (Managing Director) Mr. Muhammad Shahzad ( Factory Manager) Miss
Shahzia (Production Manager) Mr. Khawar (Senior Quality Manager) Mr. Zameer Haidr
(Quality Manager) Miss Mariam Riaz (MR)
Besides that, I would to appreciate my internship supervisor Miss Mariaum Riaz. I am very
thankful to her for the supervision and support that she gave truly helped the progression and
smoothness of the internship program.
As the most important person, I also want to thank to Mr. Muhammad Shahzad (Factory
Manager) that giving me chance and opportunity to work in his organization in order to complete
my internship session.
Any omission is this brief acknowledgment does not mean lack of gratitude.
Thank you….
3
Contents 1 INTRODUCTION AND HISTORY OF COMPANY ........................................................... 7
2 BRANDS ................................................................................................................................ 8
3 BISCUITS BRANDS WITH THEIR PRODUCTS ............................................................... 8
3.1. INNOVATIVE ................................................................................................................. 8
3.2. CUTEES ........................................................................................................................... 9
3.3. TASTE MAKERS ............................................................................................................ 9
4 WAFERS BRAND WITH THEIR PRODUCTS ................................................................... 9
4.1. CUTEES ........................................................................................................................... 9
4.2. TASTEMAKERS ........................................................................................................... 10
4.3. INNOVATIVE ............................................................................................................... 10
4.4. FRISKY .......................................................................................................................... 10
5 EQUIPMENTS AND MACHINARY USED IN INDUSTRY ............................................ 11
5.1. WEIGHING BALANCE................................................................................................ 11
5.1.1 MECHANICAL BALANCE .................................................................................. 11
5.1.2 ELECTRONIC SCALE .......................................................................................... 11
6 WAFERS .............................................................................................................................. 12
6.1. WAFER MIXER ............................................................................................................ 12
6.2. WAFER OVEN .............................................................................................................. 12
6.3. COOLING TOWER ....................................................................................................... 12
6.4. CREAM SPREADING MACHINE .............................................................................. 13
6.5. WAFER CUTTINGMACHINE ..................................................................................... 13
6.6. CREAM MIXER ............................................................................................................ 13
7 BISCUITS ............................................................................................................................. 14
7.1. MOULDER .................................................................................................................... 14
7.2. BISCUITS BAKING OVEN ......................................................................................... 14
7.2.1 TYPES .................................................................................................................... 14
7.3. OVEN ZONES ............................................................................................................... 14
7.3.1 ZONE 1 (PUFFING ZONE) ................................................................................... 14
7.3.2 ZONE 2 (BAKING ZONE) .................................................................................... 15
7.3.3 ZONE 3 (COLORING ZONE) ............................................................................... 15
7.4. CONVEYER BELT ....................................................................................................... 15
7.5. BISCUITS STACKER ................................................................................................... 16
7.6. PACKING MACHINE .................................................................................................. 16
4
8 INGREDIENTS OF DIFFERENT BISCUITS ..................................................................... 17
8.1. DIGESTIVE ................................................................................................................... 17
8.2. JUMBOO ....................................................................................................................... 17
8.3. SNOPER......................................................................................................................... 18
8.4. CHOC ‘N’ CHIP ............................................................................................................ 18
9 ROLE OF INGREDIENTS................................................................................................... 19
9.1. WATER .......................................................................................................................... 19
9.2. FLOUR ........................................................................................................................... 19
9.2.1 FUNCTIONS .......................................................................................................... 19
9.3. RAISING AGENTS ....................................................................................................... 20
9.3.1 SODIUM BICARBONATE (NAHCO3) ............................................................... 20
9.3.2 AMMONIUM BICARBONATE............................................................................ 20
9.4. FAT ................................................................................................................................ 20
9.5. PROTEIN ....................................................................................................................... 21
9.6. SUGAR .......................................................................................................................... 22
9.7. SALT .............................................................................................................................. 22
9.8. SKIMMED MILK POWDER ........................................................................................ 22
9.9. EMULSIFIERS .............................................................................................................. 23
9.10. EGGS .......................................................................................................................... 23
9.11. BUTTER ..................................................................................................................... 24
9.12. ARTIFICIAL FLAVORS ........................................................................................... 24
9.13. SMS (SODIUM METABISUPHITE) ........................................................................ 24
9.14. DEXTROSE ............................................................................................................... 24
10 BISCUITS ............................................................................................................................. 25
10.1. FLOW DIAGRAM ..................................................................................................... 25
10.2. PROCESSING LINE FOR BISCUITS ...................................................................... 26
10.2.1 RAW MATERIAL.................................................................................................. 26
10.2.2 LAB ANALYSIS .................................................................................................... 26
10.2.3 STORAGE .............................................................................................................. 26
10.2.4 WEIGHING & SIFTING ........................................................................................ 26
10.2.5 MIXING .................................................................................................................. 27
10.2.6 METAL DETECTOR (CCP) .................................................................................. 27
10.2.7 ROLLING AND SHAPING/ CUTTING ............................................................... 27
10.2.8 BAKING ................................................................................................................. 28
5
10.2.9 CHANGE DURING BAKING ............................................................................... 28
10.2.10 COOLING ........................................................................................................... 29
10.2.11 STACKERS ........................................................................................................ 29
10.2.12 PACKING ........................................................................................................... 29
10.2.13 STORING............................................................................................................ 30
10.2.14 DISPATCHING .................................................................................................. 30
10.3. QUALITY DEFECTS IN BISCUITS ........................................................................ 30
10.4. PACKAGING DEFECTS .......................................................................................... 30
11 WAFERS .............................................................................................................................. 31
11.1. INGRIDIENTS ........................................................................................................... 31
11.2. FLOW DIAGRAM ..................................................................................................... 32
11.3. PROCESSING LINE FOR WAFERS ........................................................................ 33
11.3.1 RAW MATERIAL.................................................................................................. 33
11.3.2 LAB ANALYSIS .................................................................................................... 33
11.3.3 STORAGE .............................................................................................................. 33
11.3.4 WEIGHING & SIFTING ........................................................................................ 33
11.3.5 MIXING .................................................................................................................. 33
11.3.6 BAKING ................................................................................................................. 34
11.3.7 COOLING............................................................................................................... 34
CREAMING ......................................................................................................................... 35
11.3.8 CREAM INGREDIENTS ....................................................................................... 35
11.3.9 CUTTING ............................................................................................................... 35
11.3.10 PACKING ........................................................................................................... 35
11.3.11 STORING............................................................................................................ 36
11.3.12 DISPATCH ......................................................................................................... 36
11.4. REQUIREMENTS FOR WAFERS ........................................................................... 36
12 LAB WORK ......................................................................................................................... 37
12.1. WHEAT FLOUR ANALYSIS ................................................................................... 37
12.1.1 GLUTEN TEST ...................................................................................................... 37
12.1.2 MOISTURE ANALYSIS ....................................................................................... 39
12.2. FAT (SHORTENING) ANALYSIS ........................................................................... 40
12.2.1 FREE FATTY ACIDS (FFA) TEST ...................................................................... 40
12.2.2 RANCIDITY TEST ................................................................................................ 42
12.2.3 SLIP MELTING POINT TEST .............................................................................. 43
6
12.3. ANALYSIS OF FINISHED GOODS ........................................................................ 44
12.3.1 WEIGHT TEST ...................................................................................................... 44
12.3.2 DIAMETER TEST ................................................................................................. 44
12.3.3 THICKNESS TEST ................................................................................................ 45
12.3.4 MOISTURE TEST.................................................................................................. 45
12.3.5 CREAM PERCENTAGE TEST ............................................................................. 45
13 FOOD PACKAGING MATERIAL ANALYSIS ................................................................. 46
LIST OF PACKING MATERIAL USED IN BISCUITS INDUSTRY ................................... 46
14 Quality................................................................................................................................... 47
14.1. DEFINITIONS ........................................................................................................... 47
QUALITY SYSTEM ................................................................................................................ 47
14.2. QUALITY CONTROL & QUALITY ASSURANCE DEPARTMENTS ................. 48
15 ASSIGNMENTS................................................................................................................... 49
15.1. ASSINMENT # 1 ....................................................................................................... 49
15.2. ASSINMENT NO: 02 ................................................................................................ 50
15.3. ASSINMENT NO: 03 ................................................................................................ 51
15.4. ASSINMENT NO: 04 ................................................................................................ 52
15.5. ASSINMENT NO: 05 ................................................................................................ 53
PROBLEMS OBERVED AT STACKER AND DURING PACKAGING ......................... 55
15.6. ASSINMENT NO: 06 ................................................................................................ 56
15.7. ASSINMENT NO: 07 ................................................................................................ 57
16 SUGGESTIONS / FEEDBACK ........................................................................................... 59
17 CONCLUSION ..................................................................................................................... 60
7
1 INTRODUCTION AND HISTORY OF COMPANY
Innovative Biscuits has been serving Pakistani consumers since2004. Today it is fully integrated
in Pakistani life, and is recognized as producers of safe, nutritious and tasty biscuits, and
participating in the race of leaders in developing and uplifting the communities in which it
operate.
Company has expanded its operations massively. The Innovative brand is now a strong
consumers’ franchise, growing the fastest of any brand nationwide, and spanning an extensive
distribution network of 250 distributors and dealers in Pakistan. Innovative believes in offering
only the very best to consumers, and keeps itself at pace with the dynamic world. The philosophy
of the company is to offer consumers greater choice of exclusive and quality confectionary
products.
In 2004 a small company was formed by Sheikh Munir Hussain. The intent was to spread joy
and cheer to children and adults alike, all over the country with sweets and candies. The
company knew that it wouldn’t be an easy task, but decided to take the brave step. A small
factory was set up in the Industrial Area of Kot Lakhpat with initial capital of 5 Million on a
land of 2.5 canals. Within a short span of time the company rapidly grew and enhanced its plant
and manufacturing equipment and shifted temporarily to a land of 10 canals at 23 KM,
Sheikhupura Road, Lahore. Currently the company is spread over 65,000 square feet with a Total
Area of Plant and Factory of more than 67 Canals.
The imported plant and equipment are purchased form World’s Best Biscuits Manufacturing
Company – United Biscuits (UK) and the Oven Baking ₒThe company at present has the capacity
to produce approximately 1.5 Tons biscuits per hour..
8
2 BRANDS A variety of products is being produced at innovative under different brand names. Innovative
has three brand names
1. Innovative
2. Cutees
3. Taste Maker
PRODUCTS
1. Biscuits
2. Wafers
3 BISCUITS BRANDS WITH THEIR PRODUCTS
3.1. INNOVATIVE 1. Jumboo
2. Goodies
3. Goodies with lemon flavor
4. Digestive
5. Peanut
6. Zeera
7. Choc N Chip
8. Xtra
9
3.2. CUTEES
1. Topper
2. Too Good
3. Pea Nut
4. Super Crunch
5. Fighter
6. Tracker
3.3. TASTE MAKERS
7. Peanuts
8. Tea Time
9. Elaichi special
10. Pista Maza
11. Kingo
12. Snoper
4 WAFERS BRAND WITH THEIR PRODUCTS
4.1. CUTEES
1. Plus Orange Wafers
2. Plus Custard Wafers
3. Plus Strawberry Wafers
4. Plus Chocolate & Vanilla Wafers
10
4.2. TASTEMAKERS
1. Orange wafers
2. Mango wafers
3. Chocolate wafers
4. Strawberry wafers
4.3. INNOVATIVE
1. Trend Orange
2. Trend Orange
3. Trend Chocolate
4. Wafers Creamy orange flavor
5. Wafers Creamy Chocolate Flavor
6. Wafers Creamy Strawberry Flavor
7. Wafers Creamy Vanilla Flavor
4.4. FRISKY
1. Orange cream wafers
2. Vanilla cream wafers
3. Chocolate cream wafers
11
4. Strawberry cream wafers
5 EQUIPMENTS AND MACHINARY USED IN INDUSTRY
5.1. WEIGHING BALANCE
Weighing balance is used to weigh different ingredients. There are
two types of weighing balance at plant.
5.1.1 MECHANICAL BALANCE
Used to weigh large quantities of materials in kilograms and have
least count of 0.01kg. Used to weigh flour & sugar.
5.1.2 ELECTRONIC SCALE
Used to weigh different ingredients in small fractions(improver,
salt etc). and have least count of 0.01g.
Figure 1.Machanical Balance
Figure 2.Electronic Scale
12
6 WAFERS
6.1. WAFER MIXER
Wafer mixer is used to mix the flour to make the batter
for wafers. Mixing strongly affected by the moisture
absorption of flour and protein contents.
6.2. WAFER OVEN
Wafer oven is used for baking wafer sheets.
The sheets formed by baking between pairs of heated
metal plates.Ovens have 65 plates and can operate on
three speeds, 18, 20 and 22. Baking time and
temperature depends on speed of oven.
6.3. COOLING TOWER
Cooling tower is used to cool the wafer sheet.It can
hold 51 sheets at a time.It directly drops the sheets
on creaming machine conveying belt.
Figure 3. Wafer Mixer
Figure 4. Wafer Oven
Figure 5.Cooling Tower
13
6.4. CREAM SPREADING
MACHINE
Cream spreading machine is used to
spread an exact amount of fat cream
onto the wafer sheets.
6.5. WAFER CUTTINGMACHINE
Wafer cutting machine is a steel wire cut machine
used to cut the wafer sheet into fingers. No of
fingers produced from one sheet depend on the
space between steel wire cut horizontally and
vertically.
6.6. CREAM MIXER
Cream mixer is used to mix
the cream, sugar, flavor and
color for proper application
of cream to the wafer sheets.
Figure 6. Cream Spreading Machine
Figure 7.Wafer Cutting Machine
Figure 8. Cream Mixer
14
7 BISCUITS
7.1. MOULDER
Mould is used to give the shape to biscuits.
Mould is different for different products.
7.2. BISCUITS BAKING OVEN
Biscuits baking oven is used to bake the biscuits.
7.2.1 TYPES
1. Direct Oven: There are number of burners on the bottom and top of the steel belt
cangaing the product for baking.
2. Indirect Oven: In this type only one large burner is present and heat in spread in oven
sections through moving air.
7.3. OVEN ZONES
At innovative, ovens are 150-200 feet long. These are tunnel type ovens. Oven has three
zones and each zone gives specific characteristics to the biscuit. Each zone has its specific
temperature and air pressure.
7.3.1 ZONE 1 (PUFFING ZONE)
In this zone leavening agents do their work, a gas produce This helps the biscuit to puff.
Figure 9. Moulder
15
7.3.2 ZONE 2 (BAKING ZONE)
In this zone of oven moisture removes and biscuit bakes.
7.3.3 ZONE 3 (COLORING ZONE)
Due to sugar caremlization occurs and browning held to give the color to biscuit.
7.4. CONVEYER BELT
It is used to convey the biscuit from one belt to
another belt.
Figure 10.Oven
Figure 11. Conveyer Belt
16
7.5. BISCUITS STACKER
Biscuits stacker is used to stack the biscuits which
facilitates in feeding the biscuits to the packaging
machine.
7.6. PACKING MACHINE
In this industry three type of packaging is done in e.g. primary, secondary and tertiary packaging.
Speed of machine is adjustable.
Figure 12.Biscuit Stracker
Figure 13.Packaging Machine
17
8 INGREDIENTS OF DIFFERENT BISCUITS
8.1. DIGESTIVE
1. Water
2. Wheat flour
3. Vegetable oil
4. Whole meal
5. Sugar
6. Glucose syrup
7. Dried skimmed milk
8. Raising agents {sodium bi carbonate, ammonium bicarbonate}
9. Salt
8.2. JUMBOO
1. Water
2. Wheat flour
3. Sugar
4. Hydrogenated vegetable oil
5. Glucose
6. Salt
7. Raising agents (Sodium Bicarbonate E500 and Ammonium Bicarbonate E503)
8. Soya Lecithin E322
9. Calcium Carbonate E170
10. Sodium Pyrophosphate E450
18
11. Artificial Flavors
8.3. SNOPER
1. Water
2. Wheat flour
3. Vegetable oil
4. Sugar
5. Corn Flour
6. Skimmed Milk Powder
7. Fresh Eggs
8. Salt
9. Leavening Agents
10. Artificial Flavor
11. Permitted Food Color
8.4. CHOC ‘N’ CHIP
1. Water
2. Wheat flour
3. Vegetable oil
4. Chocolate chips
5. Raising agents
6. Salt
7. Artificial flavor
8. Permitted food color
19
9 ROLE OF INGREDIENTS
9.1. WATER
Water is a basic ingredient in baking. It facilitates mixing of ingredients and other steps of
processing.
There are certain functions of water which include:
1. It makes possible the formation of gluten.
2. It wets and swells the starch.
3. It assists in controlling the temperature of dough. By adding cold or warm water the
temperature of the dough can be regulated.
4. It dissolves salts, suspends and distributes non-flour ingredients uniformly.
9.2. FLOUR
Flour is a very important ingredient which imparts unique appearance, characteristic to the
biscuit. In biscuit manufacturing only endosperm portion of wheat is used & is separated from
germ & bran, which is called as: white flour, Maida”
9.2.1 FUNCTIONS
1. Flour provides the structure in baked goods
2. Acts as a binding agent
3. Acts as an absorption agent
4. Affects the taste
20
5. Provides nutrition in final product
6. Retain shape and volume after baking
7. Major constituent of biscuit.
9.3. RAISING AGENTS
9.3.1 SODIUM BICARBONATE (NAHCO3)
1. It is also known as baking soda.
2. It releases carbon dioxide on being exposed to moisture and acid.
3. In baking, it is used as leavening agent and give volume to breads, cookies, cakes.
4. The amount added to dough affects the volume and texture of the product.
5. Excess use of baking soda leaves an after- taste and gives a light color to the finished
product.
6. Often used in chocolate cakes to raise the pH of cocoa.
9.3.2 AMMONIUM BICARBONATE
1. It is used to a small extent as a leavening agent.
2. Its use is limited to a certain types of cookies.
3. Its advantage is that it decomposes into two gases and does not leave a solid residue.
9.4. FAT
1. Provides nutrition, flavor.
2. Aids in development of physical structure.
21
3. Fat provides shortness and tenderness.
4. Helps in flavor development.
5. Help in Emulsification.
6. Help in Aeration (creaming).
7. Helps in heat transfer.
9.5. PROTEIN
Flour is produced from the endosperm of the wheat. The endosperm contains about 80 percent of
the total amount of protein in the whole kernel. Protein content determines how much water flour
can absorb the greater the amount
1. It contains four types of proteins:
2. Albumin,
3. Globulin,
4. Glutenin (controls strength & structure of biscuit)
5. Gliadin (gives elasticity to the dough)
Gluten Formation
Glutenin & Gliadin are insoluble proteins. When wheat flour is mixed with water and kneaded,
the glutenin and gliadin proteins bond with the water and link and crosslink with one another to
form sheets of a flexible, resilient film called gluten.
22
9.6. SUGAR
1. Sugar provides sweetness.
2. It enhances flavor and aroma.
3. It helps in browning by caramelization reaction.
4. Imparts color to the bakery items.
5. Imparts sweetness
6. Fuel for yeast
7. Extents shelf life by increasing its moisture retention.
9.7. SALT
1. It is mainly added for taste.
2. Most effective concentration is around 1 – 1.5 % based on flour weight
3. Used for flavor & flavor enhancing properties
4. It should be completely soluble in water.
5. It should be pure, free from lumps.
6. Prevents the growth of undesirable bacteria in yeast raised dough.
9.8. SKIMMED MILK POWDER
When a fat is separated from the milk for cream & butter manufacture, a white fluid, rich in
lactose & protein remains. This is called Skimmed Milk & when this skimmed milk is dried by
evaporation or by spray-drying, it is called as “Skimmed Milk Powder”.
23
1. It is used to give flavor, texture & aids in surface coloring.
2. It has a binding effect on flour protein, creating a toughing effect.
3. Improves flavor & is an important moisture retaining agent.
9.9. EMULSIFIERS
It is added to the dough during mixing to mix two immiscible things.
Some of common ones are
1. Monoglycrides.
2. Calcium sterol lactate.
3. Sodium steroyl lactylate.
4. Soya lecithin is being used as emulsifier in biscuits.
9.10. EGGS
1. Eggs contribute flavor to the product.
2. Act as emulsifier.
3. Helps in smooth & even texture of the finished product.
4. Contributes to the structure of baked product.
5. Contribute color, nutritional value & desirable flavor.
6. Improves characteristic organoleptic qualities of biscuit.
24
9.11. BUTTER
1. Butter is made from cream and has a fat content of at least 80 percent.
2. Butter imparts a good flavor without a greasy mouth feel to baked goods because it melts
at body temperature.
3. It adds valuable nutrients to the biscuits.
9.12. ARTIFICIAL FLAVORS
1. These are used to enhance flavor of product.
2. God quality and food grade flavors must be used.
9.13. SMS (SODIUM METABISUPHITE)
1. Used in very small quantity to modify the gluten quality chemically.
2. It causes the gluten to become more extensible & less elastic, therefore reduces the
shrinkage of dough pieces as they are baked
9.14. DEXTROSE
1. It is a simple sugar, usually made from corn starch.
2. Also helps in baking.
3. Major role in taste, texture & color development.
25
10 BISCUITS
10.1. FLOW DIAGRAM
Dispatch
Storing
Packing
Sorting
Stacker
Cooling
Baking
Rolling and shaping
Mixing
Weighing Sifting
Storing
Lab analysis
Raw material
26
10.2. PROCESSING LINE FOR BISCUITS
10.2.1 RAW MATERIAL
Raw material used for different biscuits is received at factory and is analyzed as described in lab
work section.
10.2.2 LAB ANALYSIS
All raw material is analyzed in Lab and those materials which fullfil the standard requirements
are then used.
10.2.3 STORAGE
If raw material passes the reception tests then it is stored in storage room. Proper storage is
necessary to avoid contamination and for quality of end product. As for flour, the bags should be
at least 1.6 feet away from walls and roof. This distance should also be between the rows. The
other raw materials are also stored properly.
10.2.4 WEIGHING & SIFTING
I. Scale all ingredients accurately.
II. Sift the dry ingredients together into a mixer.
27
10.2.5 MIXING
Combine the liquid ingredients. Add the liquid to the
dry ingredients. Mix just until the ingredients are
combined and soft dough is formed. Do not over mix.
The mixing temperature should be 25 to 29°C.
10.2.6 METAL DETECTOR (CCP)
A metal detector is present before the cutting Its function is to detect the metal or other
contaminants from ingredients or at previous steps of manufacturing process.
It detects
1. Fe 5mm
2. Non Fe 5mm
3. Stainless steel 5mm
10.2.7 ROLLING AND SHAPING/ CUTTING
After proper mixing, the dough is dropped in the hopper. Here the rollers present in the hopper
make the small fragments of dough. The conveyor belt carries these fragments towards the
mould. The rolling mould then forms and cuts biscuits into the shape made on the mould. All this
process is handled mechanically. Also this process can be carried out by wire cutter
Figure 14 Mixer
28
10.2.8 BAKING
It is the technique of prolonged cooking of food by dry heat acting by convection The raw
prepared biscuits enter in oven through conveyer. Where they are heated at temperature 240 to
245°C. This is a continuous mechanical process. The biscuits remain within oven for 5 minutes.
Oven
At innovative, ovens are 150-200 feet long. These are tunnel type ovens. Oven has three zones
and each zone gives specific characteristics to the biscuit.
Some types of ovens also have five zones.
Following are the physical and chemical changes which occur in oven, when dough piece is
passed on to oven.
10.2.9 CHANGE DURING BAKING
10.2.9.1 PHYSICAL CHANGES
1. Formation of crust
2. Melting of fat
3. Gas expansion in dough piece due to Co2 expansion at higher temperatures
4. Water converted into steam
10.2.9.2 CHEMICAL CHANGES
1. Gas formation
2. starch gelatinization
3. Protein changes
4. Caramelization of sugars
29
10.2.10 COOLING
After baking, cooling is done. Cooling is done at
room temperature. The biscuits move on a long
belt at room temperature which cools the biscuits.
The cooling time can be increased or decreased by
changing the speed of the cooling belt.
10.2.11 STACKERS
The function of stacker is that it makes
arrangement of biscuits which facilitates in further
operations.
In this step the following things are assured that
I. The weight of 10 biscuits according to
standard
II. There is no color variation.
III. The biscuits are sound and separate from each
other.
IV. The diameter is according to standard
10.2.12PACKING
The biscuits are manually placed in plastic tray and are packed mechanically in wrappers. Then
the packets are packed in boxes and then are covered by cellophane paper.
The Mfg. and Expiry dates are mentioned on the packing.
The following particulars should be clearly and indelibly marked on label on each pack:
Figure 15.Cooling Conveyer
Figure 16. Strackers
30
1. Name or trade-name of the biscuit,
2. Name of the biscuit manufacturer,
3. Batch or code number,
4. Net weight in grams (g) or kilograms (kg), and
5. The statement ‘Permitted flavoring and coloring agents used”
10.2.13STORING
The finally packed product is stored in ware house or dispatch room.
10.2.14 DISPATCHING
Then the product is dispatched to market.
10.3. QUALITY DEFECTS IN BISCUITS
1. Over baked
2. Under baked
3. Small diameter
4. Broken biscuits
5. Less weight
6. Over weight
7. Shape error
8. thickness problem
9. width problem
10.4. PACKAGING DEFECTS
1. Fin seal and end seal problems
2. Wrapper printing problems
3. Lose packagin
31
11 WAFERS
WAFERS
It is a small crispy food product which is filled with
layers of flavored cream. Wafers are a very specialized
type of biscuit requiring special equipment for
production. They may be chocolate enrobed or included
in molded chocolate
11.1. INGRIDIENTS
1. Water
2. Wheat flour
3. Grinded sugar
4. Corn oil
5. Cream
6. Salt
7. Soya lecithin
8. Artificial color
9. Artificial flavor
10. Sodium bicarbonate
11. Skimmed milk powder
12. Dextrose powder
13. Antioxidant
14. Hydrogenated vegetable oil
32
11.2. FLOW DIAGRAM
Dispatch
Storing
Packing
Cutting
Creaming
Cooling
Baking
Sheeting
Mixing
Weighing Sifting
Storing
Lab analysis
Raw material
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11.3. PROCESSING LINE FOR WAFERS
11.3.1 RAW MATERIAL
Raw material used for wafers is received at factory and is analyzed. Most of the ingredients in
biscuits and wafers are same. There are differences in processing.
11.3.2 LAB ANALYSIS
All raw materials is analyzed in Lab and those materials which fulfill the standard requirements
are then used.
11.3.3 STORAGE
If raw material passes the reception tests then it is stored in storage room. Proper storage is
necessary to avoid contamination and for quality of end product.
11.3.4 WEIGHING & SIFTING
i. Scale all ingredients accurately.
ii. Sift the dry ingredients
11.3.5 MIXING
1. Add chilled water in the mixer.
2. Add the dry ingredients to water in the mixer.
3. Mix them until the ingredients are uniformly mixed.
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4. It takes about 8-10 minute to mix properly
11.3.6 BAKING
Then this batter is shifted to the dies of the oven. The batter is transferred through a nozzle by
pumping. Here it is heated at 150°C for three and half minutes. The heated die bakes, gives
specific shape and forms sheet of the wafer.
11.3.7 COOLING
i. After baking these sheets are cooled on the moving belt.
ii. It takes about two and half minutes for cooling.
iii. Then these sheets are transferred to the creaming section.
iv. Here the broken sheets are separated from sound ones.
v. The weight of 3 plane sheets after cooling should be 120 to 125 gram.
Figure 17. Wafer Sheets Cooling Tower
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CREAMING
The cream is spread on a roller of the creaming machine
from the hopper.The sheets pass under this creaming
roller and get creamed. The machine is automatically set.
Two sheets with cream and one without are attached to
each other. Here the weight of sheets with cream should
270 to 280 gram.The cream is prepared in a separate
cream mixing machine.
11.3.8 CREAM INGREDIENTS
1. Fat/Cream
2. Sugar
3. Color
4. Flavor
5. cocoa powder for chocolate cream
6. vanilla powder for vanilla cream
11.3.9 CUTTING
The sheets are cut with a cutting machine and the sound wafers are shifted to the packing section.
11.3.10 PACKING
The wafers are manually placed in plastic tray and are packed mechanically in wrappers. Then
the small packets are packed in large packaging and then are covered with cellophane paper.
The Mfg. and Expiry dates are mentioned on the packing.
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Each container must contain
1. Name or trade-name of the biscuit,
2. Name of the biscuit manufacturer,
3. Batch or code number,
4. Net weight in grams (g) or kilograms (kg), and
5. The statement ‘Permitted flavoring and coloring agents used.
11.3.11 STORING
The finally packed product is stored in ware house or dispatch room.
11.3.12 DISPATCH
Then the product is dispatched to market.
11.4. REQUIREMENTS FOR WAFERS
1. Wafers will be properly baked and will not show signs of under baking or over baking.
2. They will be crisp, crunchy and light in texture. The design impressed on them, if any
will be clear.
3. They will have an agreeable odor typical of well-baked wafers, and will be free from
soapy or other objectionable flavors.
4. They will not have insect and fungus infestation.
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12 LAB WORK
In lab all the raw material and finished products are tested if fulfill the mention criteria than it is
used. In lab following raw material are analyzed.
12.1. WHEAT FLOUR ANALYSIS
Flour is one of the most important and basic ingredients of the biscuits. The quality of the
product will depend upon the quality of flour. So in order to ensure the quality following test are
performed in laboratory.
1. Gluten Percentage
2. Moisture Percentage
12.1.1 GLUTEN TEST
Gluten is a Wheat flour protein formed by two components
Gliadin: Elasticity in dough is due to gliadin.
Glutenin: Resistant to extension dough is due to glutenin.
On the basis of Gluten percentage, flour is divided into three categories.
Table 1.Types of Flour on the basis of Gluten percentage
Soft Flour Semi Hard Flour Hard Flour
7-9% 9-11% More than 11%
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GLUTEN TEST PROCEDURE
APPARATUS
1. Petri dish
2. Mixing bowl
3. Glass container
4. Hard paper
5. Knife
6. Electric weighing balance
7. Oven
PROCEDURE
1. Take 20 grams of flour sample in a Petri-dish by using electrical balance. Put this sample
in a container for mixing.
2. Add 10 ml water in it and start mixing it, preferably with one figure.
3. Keep on mixing and make its dough until flour sample is completely mixed and gluten is
formed. Then take water in the same container and dip the dough in it for 30 minutes
after that start washing sample dough.
4. Washing is carried out in order to remove starch from it. After the removal of starch, take
a small piece if hard paper and dry it.
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5. Weigh it and put the wet gluten on it and spread on whole paper. After spreading, give it
cuts with the help of a sharp knife.
6. Now place it in oven at 110 °C for the drying. When all the moisture is dried out, weigh
it and calculate the gluten % age.
CALCULATIONS
1. Weight of sample w1
2. Weight of hard paper w2
3. Weight of wet gluten w3
4. Wet gluten % age w3/w1 x 100
5. Weight of gluten and hard paper w4 =w2 + w3
6. Weight of gluten and hard paper after drying w5
7. Weight of dry gluten w6 = w4- w2
8. Dry gluten % age w6/w1 x 100
12.1.2 MOISTURE ANALYSIS
Another important aspect of flour quality is the moisture percentage. Moisture percentage affects
the use of water in recipe. If moisture is high in flour, then less water will be used in dough
making and if moisture percentage of flour is low, then more water is required for the dough
making.
If the moisture percentage of the flour is high then the standard of the factory, then flour is
accepted for production on rebate.
MOISTURE TEST (WITH MOISTURE ANALYZER)
APPARATUS
1. Moisture analyzer
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PROCEDURE
Take 5 grams of the flour sample in a silver plate and spread it in the plate. Put it in moisture
analyzer at a temperature of 105 0C. Moisture analyzer will show moisture percentage in few
minutes.
Moisture % age =4.6%
12.2. FAT (SHORTENING) ANALYSIS
Fat is used in biscuit for many reasons like it make the product more palatable, helps in baking,
helps in the formation of crisp along with the other ingredients.
Following tests are performed in fat:
1. Free Fatty Acids (FFA)
2. Rancidity
3. Slip Melting Point (SMP)
12.2.1 FREE FATTY ACIDS (FFA) TEST
Free fatty acids are tested in the fat coming to the industry before using in production. This test is
performed because it is an indicator of time taken by the product to be rancid. If FFA of the fat is
high the product made from it will get rancid soon as compared to the fat with less FFA. FFA
can combine with the oxygen in the environment and product gets rancid as a result.
APPARATUS
1. 3 glass cylinders (50 mL)
2. 250 mL flask
3. 3 pipettes
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4. Sucker
5. 50 mL burette
6. Digital weighing balance
CHEMICALS
1. Ethanol
2. Fat sample
3. Di-ethyl ether
4. 1% Phenolphthalein solution
5. 0.1N KOH solution
PROCEDURE
1. Take 25 ml of Ethanol and 25 ml of Di-ethyl ether in flask.
2. Add 2-3 drops of phenolphthalein indicator solution and shake it.
3. Titrate it against 0.1N KOH till light pink color appears. This is done in order to
neutralize the solution.
4. Take10 grams sample of fat in the same flask, and mix it.
5. The burette must be prepared before using. First, rinse the burette with distilled water.
Close the stopcock and put 10 mL of KOH in the burette. Swirl the KOH so that all of the
burette has been coated with the KOH. Drain the NaOH through the tip. This first rinse is
to coat the burette with the solution. Close the stopcock and place another 10 mL KOH in
the burette. Swirl again and drain through the tip. The second rinse is to make certain that
only your KOH is on the inside of the burette and not water.
6. After preparing the burette, fill it with KOH solution. Drain some of the KOH solution
down to make sure the tip of the burette is filled with NaOH and no air bubbles are in the
tip or drops hanging out of the tip. Air bubbles can be removed from the tip by thumping
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the tip while the solution is flowing. Dry the tip of the burette and check to see if the
burette is leaking.
7. In this experiment the burette contains KOH.Titrate the fat solution until the colorless end
point appears.
CALCULATIONS
Weight of fat sample w
Initial reading of burette V1
Final reading of burette V2
Volume of KOH used V= V2- V1
FFA% 2.82 x V/w
12.2.2 RANCIDITY TEST
APPARATUS
1. 100 mL flask
2. Scapula
3. Three pipette
4. Sucker
5. Test tube with stopper
6. Digital weighing balance
7. Test tube holder
8. Test tube stand
9. Oven
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CHEMICALS
1. Fat sample
2. 37% conc. HCl
3. 0.1% Phloro glucinol (solution made in ethanol/ether solvent)
PROCEDURE
1. Take a small amount of fat sample in the flask with the help of specula.
2. Take it in oven for some time so that it melts completely.
3. Take 5 grams of molten fat in test tube and add 5 gram 37% concentrated HCL. Shake
and add 5 grams of Phloroglucinol (0.1 %).
4. Again shake and observe the color.
5. Change in color will be rejected.
6. If color match with original sample then it is ok.
7. Rancidity in the given sample = Nil
12.2.3 SLIP MELTING POINT TEST
Melting point is checked in order to check the behavior of fat in the product. If melting point is
low then, fat in the product will melt at lower temperature thus affecting the quality of the
product. If the melting point is high then it will affect the baking process during production.
APPARATUS
1. Test tube
2. Test tube holder
3. Test tube stand
4. Burner
5. Two capillary tubes
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6. Thread
PROCEDURE
1. Take a test tube and put some fat sample in it and melt it on the burner while holding it
with the test tube holder.
2. When all the fat in the test tube melts pace it in stand. Take tow capillary tubes and dip
their one end the melted fat sample.
3. Take ½ - 1 inch of the sample in them and put these capillary tubes in freezer for about
five minutes.
4. Take water bath and arrange the temperature of water bath to 10 °C or less than this.
5. Tie these capillary tubes with the thermometer and put them in the water bath and in the
water bath. Temperature will start rising. When fat will melt, it will slip and move in
upward direction, note this temperature carefully.
12.3. ANALYSIS OF FINISHED GOODS
PHYSICAL CHARACTERISTICS
1. Color
2. Weight
3. Diameter
4. Thickness
5. Moisture
6. Cream%
12.3.1 WEIGHT TEST
10 biscuits are taken from the line randomly. Then the weight is taken by the digital weighing
balance. The weight of both unbaked and baked biscuits is taken.
12.3.2 DIAMETER TEST
45
To determine the diameter (D), Ten cookies were placed edge to edge. The total diameter of the
six cookies is measured in mm by using a ruler. The cookies are rotated at an angle of 90° for
duplicate reading. This is repeated once more and average diameter is reported
in millimeters.
12.3.3 THICKNESS TEST
To determine the thickness (T), Ten cookies are placed on top of one another. The total height is
measured in millimeters with the help of ruler. This process is repeated thrice to get an average
value and results are reported in mm.
12.3.4 MOISTURE TEST
Moisture of the finished products (biscuits) is tasted by moisture analyzer. Take biscuits and
grind them in grinder and take 2-3 grams in silver plate and place in moisture analyzer and note
the moisture percentage.
Moisture % age of sample =1.6%
12.3.5 CREAM PERCENTAGE TEST
In order to determine the cream percentage, first of all note the weight of the whole biscuit. Then
remove the cream from the biscuits and weigh the cream and calculate the cream percentage.
Cream Percentage in a given sample:
CALCULATIONS
Weight of whole biscuit 0.9941 grams
Weight of cream 2.1030
Cream % age 2.1030x100/10.994
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13 FOOD PACKAGING MATERIAL ANALYSIS
Food packaging
Is packaging of food. It requires protection, tampering
resistance, and special physical, chemical, or biological
needs. It also shows the product that is labeled to show
any nutrition information on the food being consumed.
LIST OF PACKING MATERIAL USED IN BISCUITS INDUSTRY
1. Films
2. Family pack
3. Dispenser
4. Master carton
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14 Quality
14.1. DEFINITIONS
The sum of characteristics of a product which influence the customer to accept or reject the
product.
The totality of features and characteristics that bear on ability of a product to satisfy
fitness for use, including safety and performance.
QUALITY SYSTEM
The organizational structure, responsibilities, procedures, processes and resources for
implementing quality management.
MANAGEMENT SYSTEM
System to establish policy and objectives and to achieve those objectives.
QUALITY MANAGEMENT SYSTEM
System to establish quality policy and quality objectives and to achieve those objectives.
CONFORMITY
Fulfillment of requirements.
NON-CONFORMITY
Non fulfillment of requirements.
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QUALITY CONTROL
Part of QMS focused on fulfillment of quality requirements.
QUALITY ASSURANCE
Part of QMS which provide confidence that quality requirements are being fulfilled.
14.2. QUALITY CONTROL & QUALITY ASSURANCE DEPARTMENTS
Quality control and quality assurance are very important for any of ISO & HACCP certified
company. At innovative, quality control inspectors control the quality by observing and
analyzing on different points of line from mixing to final packaging. Quality control is, actually,
attached with production department and there is a separate department for quality assurance.
MIXING
At mixing, the mixing incharge note and write all the ingredients on register. He ticks mark the
ingredients when they are being poured in mixing machine. The quality control inspector visit
and note that all the ingredients are mixed in the batch or either of them is missing. So mixing is
first check point.
CUTTING
On cutting the most important thing is the size of the biscuits. The biscuits may come of small
size or large size. QC inspectors notes the weight of ‘10’ biscuits and matches it with the
standard which is specific for each variety of biscuit. If there is problem in weight of biscuits
then at the time it is controlled by cutting incharge.
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OVEN
After that the biscuit enters in to the oven. Immediately when biscuit comes out of the oven, it is
observed for the shape, size i.e. length, width, thickness. For this purpose a gauge is used. The
size of gauge is specific for each variety of biscuit. The weight of ten biscuits is taken here again
to assure the quality. Here the biscuit’s weight is about 10 gram less than before entering to the
oven because 10g is moisture is evaporated during baking in oven and most of this moisture is
evaporated during first and second zone of oven.
PACKAGING
After oven, when product enters in packaging area, QC inspectors observe the biscuits, which are
over baked and under baked. Such biscuits are removed from stacking conveyor and never
allowed to pack in order to ensure quality. In packing unit efficiency of packing machines are
tested and controlled. When product is packed in family pack or in half roll pack, the leakage in
plastic film is observed by dipping the pack in water. If water enters in the pack, this shows that
product is not packed properly
15 ASSIGNMENTS
15.1. ASSINMENT # 1
What is baking loss and how it is measure?
Dough losses it weight by removal of gasses and moisture and by a small amount of dough that
sticks to the mixer. This amount of loss of averages is about 2 percent. Dough also loses its
weight during the proofing, baking and cooling. These losses occur usually averages about 11
percent. These losses must be
Taken into consideration when constructing a bread formula — the total percentage of loss
equals to 13 percent.
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Formula:
Wet weight of dough -dry weight of biscuit ÷ unbaked weight of biscuit×100
Observations
Table 2. Baking Losses of Biscuits
Baking Loss Baking Loss Baking Loss
15% 14.1% 13.5%
13% 13.7% 14.62%
11.5% 12.9% 11.3%
12.5% 11.34% 12.1%
14.5% 15.92% 15.4%
15.2. ASSINMENT NO: 02
1. HOW BISCUIT END LNES ON STEEL PLATE TURN INO BLACK AFTER
BAKING? WHAT IS REASON BEHIND THEM?
2. TOTAL BATCH CONSUPTION TIME?
3. Green trays are used for displacement of biscuits?
HOW BISCUIT END LNES ON STEEL PLATE TURN INO BLACK AFTER BAKING?
WHAT IS REASON BEHIND THEM?
Reasons
1. Low weight of unbaked biscuit
2. Having a space r gap between biscuit
3. Due to high temperature
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TOTAL BATCH CONSUPTION TIME?
From cutting to after baking = 7 min 10 sec.
Cooling Time= 8 min
Cutting to cooling = 15 min
Baking time = 8 min 20 sec
GREEN TRAYS ARE USED FOR DISPLACEMENT OF BISCUITS
No. of lines of biscuit in one tray =8 lines
No. of rows in trays =4
No. of biscuit per line =67
1 batch avers. Wt. = 436kg
No. of batch produce/ day =22
No. of carton from 1 batch =36
1 tray wt. without lid =9.91 kg
Lid wt. =0.73 g
1 carton of half rolls wt. =8.09g
With lid weight of tray = 10.64g
15.3. ASSINMENT NO: 03
IF SPEED OF PACKING MACHINE tp IS 210 THEN WHAT IS TOTAL PRODUCTION
OF CARTONS IN ONE HR. AND 1 DAY?
Speed of PM 210
Biscuit in one box 24
No.of box in one carton 18 so:
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= 210×60
= 12600 pack
= 12600/24
= 525 box in 1 hr.
= 525/18
= 29.6 no. of carton in 1 hr.
= 29.6×12
= 355 carton.
NO OF CARTON / BATCH?
Batch wt = 420kg
Baking Loss =15%
Wastage =3%
Wt of I carton =10.31kg
420-15% - 3% =346.29kg
Dough wt /wt of 1carton in kg
=346.29kg/10.31
=33.58 carton/batch
15.4. ASSINMENT NO: 04
NO OF BROKEN BISCUITS APPEAR IN 1 HR
In one hr. double biscuit appear = 3.6kg
One bath wt = 267kg
Moisture loss = 267-16%
= 224.28
1 batch time w.r.t time and motion study
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= 1hr.
= 3.6/224.28×100.
= 1.605%
Reasons for the wastage of Biscuits
1. Broken biscuit
2. Over baking
3. Color variation
4. Shape variation
5. Labour inexperience
6. Poor Handling
7. Joint biscuits
8. Texture Problem
15.5. ASSINMENT NO: 05
What are line clearance activities (SOPs) and operational time of line?
Problems observed at stacker and during packaging.?
LINE CLEARENCE ACTIVITIES (SOPs)
Activities (SOPs) at cutting section
1. Belts and Hopper are cleaned.
2. Mixer is cleaned.
3. Hopper is cleaned.
4. Dough feeding conveyer is cleaned.
5. Die is cleaned or changed accordingly.
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6. Roller of die is cleaned with air pressure.
7. Stitching of belt is checked.
8. Floor is cleaned.
9. Temperature of room and dough are checked.
Activities (SOPs) at oven section
1. Oven temperature is adjusted.
2. Wasted is cleaned and stacked into yellow trays.
3. Steel belt is cleaned with dough so that product bottom does not get contaminated by
burnt residues of biscuits, baked before.
4. Stitching of cooling conveyer belt are checked.
5. Rollers are cleaned.
Activities (SOPs) at stacker
1. Diameter of stacker rows is adjusted.
2. Rework trays are cleaned.
Activities for packaging section
1. Reels of packaging machines are checked.
2. Waste/ rework trays are cleaned.
3. Packaging machine is cleaned for any residues of already packed product.
Operational activities
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1. Cutting started at 7:50 AM
2. Time when first row came out of oven = 7:59 AM
3. Time when product reached at stacker = 8: 06 AM
4. Packaging material issued at 8:00 AM
5. Labor online at 8:30 AM
PROBLEMS OBERVED AT STACKER AND DURING PACKAGING
Problems observed at stacker
1. Dark color biscuits
2. Edges of biscuits are broken
3. Light color biscuits
4. Length problem
5. Diameter less/more
6. Low weight
7. Over weight
8. Height problem
9. Thickness problem
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Problems observed during packaging
1. Fin seal and side seal are not properly sealed
2. Loose packaging
3. Eye mark problem
4. Air leakage
5. Broken biscuits within packets
6. Date printing problem
7. Packet burnt due to high temperature
8. Empty packets
9. Short filling /over filling
15.6. ASSINMENT NO: 06
If the target of production is 300 carton of HR in 12 hr shift and Available packaging
machines are 2, what will be the speed of Machine?
No of biscuits in one pack = 10
No of packs in one box = 6
No of box in one in one carton= 24
No of biscuits in one carton= 10×6×24= 1440
No of biscuits in 300 carton= 1440×300
=4320000
No of biscuits in one hr= 4320000/12
=36000
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Speed of machine= speed of machine × no of machine ×no of biscuits in one pack
× no of pack in one Box× no of box in one carton
125×2×10×6×24
=36000
Speed of machine= 125
15.7. ASSINMENT NO: 07
PROBLEMS IN WAFER SHEET DUE TO MIXING CORRECTIVE ACTION
1. Water and lecithin are not measured properly that cause thick and thin problem in wafer
sheet.
2. Underdeveloped and overdeveloped are dependent of mixing time that cause problem in
wafer sheet,
3. If batter is overdeveloped then more gluten will develop that cause chipping of sheet.
4. If batter in underdeveloped then the corner of sheet will not be formed.
5. If sheet weight is less then less water is used about 5 liters less.
6. If sheet weight is more, then more water is added.
7. If sheet is soft then we use less soda, if sheet is hard then more soda is added.
8. If sheet is hard then more corn oil is used.
9. If sheet is being separate after baking then amount of soda is reduced.
10. If sheet is soft then more salt is added to strengthen the gluten network.
11. If sheet is sticking with oven plate then more lecithin is added
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CPM of cutter is
110
Temperature of dough was
21C̊
CCPs in Biscuit Plant
1. Dough temperature
2. Room temperature
3. Metal detector
4. Contamination of foreign material
5. Cutter arrangement
6. Knife sharpness
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16 SUGGESTIONS / FEEDBACK
1. Packaging of Frisky is very attractive.
2. All staff is very cooperative.
3. Products name and trademark logo should be unique and have no resemblance with other
as it has bad effect on consumer.
4. Floors in mixing should be sanitized at least one time in a day.
5. For belt stitching there should be a stitching machine as hand stitching may cause
contamination.
6. Mixing of cream in cream bite section must be separate.
7. Less co-operation between QA department and Production department.
8. Mess should be improved and timetable should be maintained.
9. Safety gloves and safety shoes should be provided to oven operators.
10. There should clean and cool drinking water for Labours.
11. There should be a hand drying facility with hand washing facility.
12. Mixer should be cleaned after every batch instead of evening.
13. There should be hand washing facility in hew hall and chocos hall.
14. Temperature of packaging area in new hall should be maintained.
15. There should be three shifts or working hrs should not more than 8 hrs.
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17 CONCLUSION
Industry in working since 2004 and continuously growing. Now company has seven biscuit
plants and four wafer plants and one plant for chocolate coated wafer plant. No one in the
industry is allowed to visit mixing except mixing men and their supervisors.
Company is ISO certified, Halal certified and Pakistan standards certified. Company is
following HACCP but not HACCP certified. Projects studied during the internship were
highly interesting and educative. The enthusiasm and interest shown by the office bearers and
managers of industry, during my internship helped me in understanding appropriately the
functioning of this Industry.
This internship program has made me realize the value of working together as a team and
gave me a new experience in working in a social environment, which challenges our mental
and physical faculties every minute. This short time internship programme provided to me an
opportunity to work in different settings and exposed me to interaction with different sets of
people. The working environment the Industry was highly motivating and inspiring.
