India Biscuits Industry

CONTENTSS.N.ChapterPage No.

1. Introduction

2. History and profile of Parle company.

3. Departments and sections

4. Role of Ingredients

5. Manufacturing process in detail.

6. Study of Defects in Biscuits

7. Testing methods of raw materials & finished products

8. Packaging materials

9. Corrugated Boxes Unit

10. Maintenance

11. ETP & R.O. Plant

12. Conclusion

Indian Biscuits Industry

Indian Biscuits Industry is the largest among all the food industries and has a turn over of around Rs.3000 crores. India is known to be the second largest manufacturer of biscuits, the first being USA. It is classified under two sectors: organized and unorganized. Bread and biscuits are the major part of the bakery industry and covers around 80 percent of the total bakery products in India. Biscuits stands at a higher value and production level than bread. This belongs to the unorganized sector of the bakery Industry and covers over 70% of the total production.

Indian Biscuits Industry came into limelight and started gaining a sound status in the bakery industry in the later part of 20th century when the urbanized society called for ready made food products at a tenable cost. Biscuits were assumed as sick-man's diet in earlier days. Now, it has become one of the most loved fast food product for every age group. Biscuits are easy to carry, tasty to eat, cholesterol free and reasonable at cost. States that have the larger intake of biscuits are Maharashtra, West Bengal, Andhra Pradesh, Karnataka, and Uttar Pradesh. Maharashtra and West Bengal, the most industrially developed states, hold the maximum amount of consumption of biscuits. Even, the rural sector consumes around 55 percent of the biscuits in the bakery products.

The total production of bakery products have risen from 5.19 lakh tonnes in 1975 to 18.95 lakh tonnes in 1990. Biscuits contributes to over 33 percent of the total production of bakery and above 79 percent of the biscuits are manufactured by the small scale sector of bakery industry comprising both factory and non-factory units.

The production capacity of wafer biscuits is 60 MT and the cost is Rs.56,78,400 with a motive power of 25 K.W. Indian biscuit industry has occupied around 55-60 percent of the entire bakery production. Few years back, large scale bakery manufacturers like cadbury, nestle, and brooke bond tried to trade in the biscuit industry but couldn't hit the market because of the local companies that produced only biscuits.

The Federation of Biscuit Manufacturers of India (FBMI) has confirmed a bright future of Indian Biscuits Industry. According to FBMI, a steady growth of 15 percent per annum in the next 10 years will be achieved by the biscuit industry of India. Besides, the export of biscuits will also surpass the target and hit the global market successfully.

The word 'Biscuit' is derived from The Latin words 'Bis' (meaning 'twice') and ' Coctus' (meaning cooked or baked).The word 'Biscotti' is also the generic term for cookies in Italian. Back then, biscuits were unleavened, hard and thin wafers which, because of their low water content, were ideal food to store.

Biscuit may be defined as a product based on cereals ( more than 60 % of its wt ) and contains less than 2.5 % moisture and has undergone several processing such as mixing, dough development, cutting etc. and finally baked in a oven at a suitable temperature.

Making good biscuits is quite an art, and history bears testimony to that. During The 17th and 18th Centuries in Europe, baking was a carefully controlled profession, managed through a series of 'guilds' or professional associations.

As technology improved during The Industrial Revolution in The 19th century, The price of sugar and flour dropped. Chemical leavening agents, such as baking soda, became available and a profusion of cookie recipes occurred. This led to the development of manufactured cookies.

The bakery industry comprises mainly of bread, biscuits, cakes and pastries manufacturing units.

The contributing factors for popularity of bakery products are

Urbanization resulting in increased demand for ready to eat convenient products.

Availability at reasonable cost.

Greater nutrition quality.

Availability of varieties of different textural and taste profiles and better taste.

The types of biscuits are-

1] Short dough or soft dough biscuits2] Hard dough biscuits3] Crackers or fermented dough biscuits1] Short dough or soft dough biscuitsThe type of dough used for these biscuits generally lacks elasticity and extensibility and are crumbly in nature. Lower amount of water used, lower mixing period, higher amount of fat, sugar added and nature of flour used to achieve these characteristics. These biscuits are made from weak flour (7 8 %) contains low protein and no special treatment is used. E.g. Parle-G.

2] Hard dough biscuit

The dough used for biscuits are elastic & extensible so as to avoid serious shrinkage after cutting. The dough used for semi-sweet biscuit is extensible and completely lacks elasticity. The characteristic is achieved by using weak flour of 8-9 % of protein, mixing for a longer time and by treatments with water and SO2 while the dough of salted biscuits are quite elastic and extensible and this characteristics can be achieved by using hard wheat flour, longer mixing period, using low fat and sugar. But more water in dough e.g Marie.

3] Crackers or fermented dough biscuits

These biscuits are characterized by crispy bite, light & laminated texture, low sweetness, salty & spicy taste. These biscuits are made from hard flour with 10-12 % protein e.g. Monaco

Biscuits are classified as per sensory attributes by ISI. These are

1] Sweet Biscuits-

These biscuits have more quality of fat and sugar, very short bite, sweet taste and flavored.

2] Semi-sweet biscuits

These biscuits have less quantity of fat and sugar and hard in texture.

3] Cracker biscuits

Inner layer is flaky, has laminar like structure. These biscuits may be fermented, oil sprayed, sprinkled with salt or sugar.

4] Cookies

These biscuits have shorter bite than sweet biscuits contain very high quantity of fat and sugar than sweet biscuits.

History and Profile of the Parle industry.

In 1929 when British ruled India a small factory was set up in the suburbs of Mumbai city to manufacture sweet and toffees and the market was dominated by famous international brands that were imported freely. Despite company called Parle products, survived & succeeded by adhering to high quality & improvising from time to time.

A decade later, in 1939, Parle products began manufacturing biscuits in addition to sweets & toffees. Having already established a reputation for quality.

The Parle brand name grew in strength with this diversification. Parle Glucose and Parle Monaco were the first brands of biscuits to be introduced, which later went on to become leading names for great taste & quality.

Apart from being the worlds largest selling biscuit Parle-G is winner of 8 Gold & 11 Silver awards at the Mond selection awards. The global standard for quality in food category.

For meeting this huge demand company has its manufacturing units located strategically all over India. There are 9 Mother units located in Mumbai, Bahadurgadh, Neemrana, Bhuj, Rudrapur, Banglore, Sitarganj, Khopoli, Nashik with 68 other contract manufacturing units.

Company has 3 contract manufacturing units abroad in Nigeria, Cameroon & Bangladesh.

Parle Products.

A number of products prepared at various units of Parle are as follows.

Biscuit Variety

Parle-GMay fair

MonacoCheeslings

KrackjackHide & Seek

Milano Hide & SeekGolden Arc

Fun CentreMarie Choice

NumkinMilk Shakti

Parle-G Magix-chocoMonaco jeera

Kreams

Confectionary Varieties

Kismi ToffeeKismi bar

MelodyChintoo bar

Mango BiteFuntoosh

PoppinsRole Mint

OrangeeKachha Mango Bite

X-haleGolgappa

Parle

Parle Biscuits Pvt. Ltd.

RIICO Indl AreaNeemranaDist Alwar(Rajasthan)Departments and Sections:-I. Quality Assurance Department

II. RMS Department

III. Production & Mixing Department

IV. BSR & Excise Department

V. HR / Personnel Department

VI. Finance & Purchase Department

VII. Engineering & Stores Department

VIII. Housekeeping & Hygiene DepartmentIX. Information Technology Department QA Quality Assurance Department.Actually QA is the heart of any food industry. It plays major role in concern with quality of raw materials & finished product. This quality is main motto of Parle.

It helps to production dept & to run the plant smoothly.

Role

1) It maintains good manufacturing practices i.e GMP for storage.

2) Maintain FIFO rules for issuing materials.

3) Implements proper formulation of products.

4) It also check & maintain online / process parameter of biscuits.

5) Testing of packing material is performed by QA.

6) QA asst. also check out shelf life of end product.

7) Quality assurance also in concern with the inspection of packets before goes to dispatch / BSR.

QA directly & indirectly helps to the company for better consumer acceptability.

Raw Material Stores Department1) RMS has raw material storage line.

2) All materials are received by RMS.

3) Maida, Sugar , Vanaspati, chemicals etc.

4) These are preprocessed here only.

5) RMS has two sifters for sifting of maida, then two grinders & sieves for sugar & at the outside there are three silos of vanaspati.

6) RMS receives material, gives sample to QA lab & after passing material are issued for use.

7) RMS keeps all records of received material, suppliers address, contact no etc.

If material is defective then it is rejected.

Production & Mixing Departmenti. Mixing is the beginning or starting point from which biscuits production begins.

ii. It is an challenge to the employee to make proper receipe to give good biscuit.

iii. All raw materials which are pre-produced are passed to mixing area.

iv. All ingredients are added in proper sequence to the mixer.

v. Fat, sugar & SMP are mixed in separate vessel called creamer while water, syrup, flavor, chemicals, are mixed in liquid vessel & flour comes from silos in other vessel.

vi. Mixing time, batch consistency, biscuit quality parameters are mainly controlled by Mixing area.

vii. Improper mixing or ignorance affect biscuit quality & good quality is the main aim of Parle.

1) Production department has various section starting from rotary section, oven section, stacker table & packaging.

2) Production planning department is concerned with total target of company & how we can achieve that target.

3) They determine in a particular time how we can achieve that target.

4) They determine in a particular time how we can achieve production on the basis of market demand.

5) production planning can satisfy consumer / market demand.

6) They maintain discipline, target, regularity in teammates.

7) Production assistant gives training to the teammates about their work to improve their efficiency. BSR & Excise1) Bounded stock room is the section where finished product is dispatched.

2) All packets which are packed in C-Boxes are passed to BSR through pallets for dispatch.

3) They keep all records of received & dispatched c-boxes.

4) Here, care is taken while dispatching materials i.e condition of vehicle, its cleanliness.

5) This material is transferred to a depot / warehouse from that marketing is done.

6) It is the responsibility of BSR department to dispatch material carefully & properly.

7) The dispatched material is distributed to various dealers & malls.

HR Department1) It is concerned with workers working efficiency, their attendance, their job details.

2) HR department also helps to teammates to improve their personality & work by Yoga courses like Art of Living.

3) It provides stationary materials to all departments.

4) All Legal & official work comes under HR.

Finance & Purchase Department1) Finance department have the responsibility to store the daily data of the financial aspect and as well as to finance at required time for any material purchasing, labor charges, electrical energy etc. They also keep records of gain or loss of industry.

2) Purchase department is consulting only with the purchase of any raw materials, packaging material and other industrial accessories and any machine or machinery part.

Engineering & Stores Department2) Engineering department is concerned with any problem of any engineering aspect of mixers, ovens, belts, dough hopper & packaging machines.

3) It also solves problem of electrical aspects.

4) Engineering department makes a layout of total plant & give their concern at which point problem arises.

5) Their observation starts from receiving of raw materials silos, storage line, process line & discharge line.

6) Stores section contains all machinery parts or any other material for processing.

7) Rubber rolls, belts, wire band, small parts of mixer chains, grease, oil are provided by store dept.

Housekeeping & Hygiene Department:-1) This department each day keeps all sections neat & clean.

2) Workers are allowed to clean mixing area, rotary section, RMS etc. to maintain & follow 5 S Rules.

IT DepartmentAs today is the era of Computers & Internet IT department is a key player in org. success or as a necessary evil. The success of the IT department lies in its ability to create, maintain and share information.

Personal Computers and Work Stations Information Technology installs, maintains, and provides ongoing user support for all of the computer hardware, software, and peripherals at the user's desktop.

Networks Information Technology is responsible for maintaining a secure and stable network environment, which is flexible and scaleable to meet the changing needs of users.

In the competitive environment implement Information Security Management System and maintain ISMS policy of company is the main function of IT.

Even it is true that corruption happens, hard drives fail, motherboards will short out, and mistakes will erase data happen rarely but taking regular Backup of all database and software avoids latter worries.

Installation and configuration of useful software like Payroll, Attendance System (HR), Material Management System, Financial Accounting System (Accounts), Depot Management System (BSR) & to provide technical support to user queries.

Installation and configuration of corporate Anti-Virus system & other Regular updation of server security patch and Anti virus.

Looking after Closed Circuit Television (CCTV) which is helping hand to ISMS.

Role of Various Ingredients used in Biscuit Industry

There are two types of ingredients used in biscuit making based on the quantity of it used in actual process. These ingredients are tested for various parameters because these ingredients are having direct effect on the quality of end product produced.

Ingredients

Major Ingredients 1] Wheat Flour

It is basic ingredient in biscuits. Flour quality can be defined as ability to produce a uniformly good end product.

Flour used in biscuit making should be free flowing, dry to touch, free from visible bran particles, creamy in color, free from musty flavor and rancid taste, fungal infection and other contaminations.

Constituents that decide the quality of wheat flour are

1. Proteins

2. Minerals or Ash

1. Proteins

Soft and medium hard flour (Protein content 8 -11 % ) is used. When wheat flour is mixed with water, gliadin & glutein fractions combine together to form Gluten proteins, which form the 80 % of total protein of wheat flour. Here gliadin contributes to viscous & extensible properties of gluten whereas glutenin is elestic & rubbery.

2. Ash

Ash content of flour is indirect measure of degree of refinement of flour. The minerals are concentrated in areas adjacent to bran coat wheat has an ash content of 1.5 %

Due to following reasons, soft wheat flour is used for Parle-G production.

1] During milling of hard wheat more of starch granules get damaged and they loose their order & crystallinity . Undamaged starch granules absorb water about 30 % of their weight whereas damaged starch granules absorb water 10 times of that amount. This high level of water absorption required for flour with greater amount of damaged Starch will interface with the spread or flow of the dough in the baking oven.

2] The flow or spread of biscuit dough during baking, taken as a measure of the flour quality, is much greater using soft wheat flour.

3] Soft wheat flour gives more tender biscuits than hard wheat flour.

2] Sugar

The chemical name for sugar is sucrose. Quantity and crystal size of sugar has big influence on biscuit texture & dimensions.

1) On caramelization during baking, it imparts a peptizing crust color & improves the general appearance.

2) On creaming with fat it helps in incorporating minute air cells in the mixture. These minute air cells form the nucleus for leavening action, which ultimately contributes to volume.

3) It tenderizes and soften the gluten

4) Improves the flavor of the product, makes biscuit hard.

5) It controls the spreading of biscuits (Spreading increases with increasing sugar )

6) Sugar contributes the nutritional value of biscuits and it is quick source of energy.

3] Fat: -

Fat helps in reducing toughness of dough formed by mixing maida & water. Fat prevents gluten formation by insulating the gluten forming proteins from the water, hence a less tough dough results.

To provide sensory attributes e.g moistness, shortness, crispness and crunchiness.

It lubricates the gluten formed allowing it to slip into a new position when sheeted or formed into biscuit shapes, without the same desire to return to its original position.

It contributes to product flavour and carries flavours.

It gives palatability to the baked products and help in the development of particular structure like volume expansion, uniform granular structure, good texture, flakiness etc. besides giving food value to it.

Facilitate aeration

They interact with starch components to alter hydration and swelling properties.

4] Inverted Sugar SyrupA sucrose solution rotates the plane of polarized light to the right. When the sucrose is hydrolyzed by acid or enzymes the rotation changes to the left (-ve direction) . This is because of the two sugars produced. Dextrose & fructose has a mean rotation to the left. This change is optical rotation is known as inversion and the resulting mixture of lower sugars is called invert sugar reaction.

Citric

C12H22O11 + H2O C6H12O6 + C6H12O6Sucrose Water Acid Glucose Fructose

As fructose is much sweeter than glucose or sucrose the invert sugar syrup is much sweeter than sucrose ( uninverted ). Sweetness of 80 % invert syrup is equivalent to ordinary sugar (weight per weight basis) Thus for the sweetness one can reduce the cost of sweetening by 20 % . It is made up by the inversion of cane sugar (sucrose) the help of citric acid. It helps to give color, flavour & decrease crystallization.

5] Water: -Water is a unique ingredient in biscuits dough. Almost all the water added to biscuit dough is subsequently removed in oven, but the quantity of water used may have an effect on the dough consistency that is why tap water used is treated properly prior to use in dough making.

In Parle biscuit plant water is treated via reverse osmosis plant to achieve required hardness and TDS. Water is always added at a low temperature to the other ingredients.

It influences the dough handling properties rheological / mechanical properties of dough system.

It acts as medium for various reactions and interactions such as gluten development, starch gelatinization, dissolution of water soluble components etc.

Act as medium for heat transfer during baking.

Affects storage life of raw as well as finished product.

It helps in aeration of biscuit to certain extent by the formation of water vapor.

Minor Ingredients: -1] Skimmed Milk Powder

It should be free from lumps & should be odorless.

It is widely used to subtle the flavor & textural improvements & to aid surface colorings & physical characteristics as well as nutritive value of the product.

The lactose is a reducing disaccharide, which is only about 16 % as sweet as sucrose but combines with proteins by the Millard reaction, under appropriate condition of heat, at the biscuit surface during baking to give attractive reddish brown hues & surface bloom.

2] Leavening Agents

Leavening is a process by which the dough is filled up with gas holes and which are retained upon baking. It is used to aerate the dough thereby render it light and porous and give the right gauge (thickness) to the biscuit.

A] Ammonium Bi-carbonate

It is an extremely volatile salt which when heated liberates CO2, NH3 gas and water.

Ammonium bicarbonate is extensively used for products, which are baked to low moisture content, for example cookies.

The major advantage of using Ammonium bicarbonate is that it does not leaves any residue after its action. Otherwise the product shall possess ammonia odour.

Its leavening effect is due to NH3, CO2 & steam due to action of heat.

NH4HCO3 NH3 + CO2 + H2O

It is responsible for puffing.

It is responsible for Millards maintains because it maintains acidity.

It is responsible for color.

B] Sodium Bicarbonate

It is important leavening chemical used widely.

It produces CO2 in presence of acid component. The acid component reacts with the soda when it gets moist to produce CO2 & steam due to action of heat.

2NaHCO3 Na2CO3 + CO2 + H2O

This is the typical example of use of double acting leavening system. In this kind of system two different leavening salts are used which release the leavening gases at different temperatures.

Here, Sodium bicarbonate acts at high baking temperature Sodium carbonate (washing soda) has a marked softening action on gluten causing and it also darken the crumb.

3] Salt :-

It is most effective concentration is around 0.75 units based on the flour weight basis. Beyond this concentration it slows down the rate of fermentation and also inhibits action of photolytic enzyme on the gluten proteins.

It causes strengthening effect & gives taste to the product.

It is used for flavour enhancing property & helps in gluten development.

4] Emulsifiers:-

These are certain chemical which help the fat and water to mix together along with flour to form homogenous mixing. They are long chain bipolar molecules having hydrophilic & hydrophobic parts.

A] Finamul

It stabilizes the emulsion of water and fat. It is added to the fat in an appropriate quantity and this mixture is added to the batch. It makes the biscuit have an uniform texture.

The other function of Finamul is as an antioxidant. It increases the shelf life of biscuit. It delays the rancidification of the fat in biscuit which produces off flavours and decreases acceptability.

B] Lecithin:-

It has very pronounced emulsifying action on fats and liquids particularly water. It facilitates the dispersion of fat in water and forms a stable emulsion. It is commercially obtained from Soyabean.

5] SMBS [Sodium Meta Bi Sulphate]

It is reducing agent normally used to modify the rheological properties of dough. The primary function of SMBS is to break the long tough protein chains to short weak ones.

It functions by donating Hydrogen atom to the disulphide bond in gluten network thus convering it to sulphyhydral bonds. Sulphydral bonds are much weaker compared to disulphide bond and thus it mellows down gluten making dough machinable & control the pH of biscuit.

It reduces the stress in dough and thus desired shaped biscuit is achieved. SMBS has a bleaching effect during storage of biscuit. The biscuit losses its color over a period of time.

6] Flavors :-Flavors play a major role in the palatable properties of biscuits. Most artificial flavors are used in biscuits, which should be stable in the baking process.

7] Citric Acid It is used for the inversion of sucrose to glucose & fructose. It also helps in liberation of CO2 from unreacted Na2HCO3 ( As on heating only half of the Na2HCO3 liberated CO2 , rest remain unreacted ) in the oven.

8] Chocolate chips, cocoa powder & Nuts

Chocolate chips and cocoa powder contributes to flavour & taste.

Nuts These are cashew bits, pistachio & almond. These are added to the biscuit, as these are nutritionally potential rich in fat & palatable.

9] Colors

It is an important ingredient as color is a major organoleptic character imparted to biscuit. Colors occurs naturally but are very expensive in most of the cases. E.g Annatto, Caramel.

Generally artificial colors are used called coal tar dyes. There are about 2000 dyes but only few are followed in food, as most of them are carcinogenic e.g Tartazine, Panceau, Brilliant Blue, Sunset yellow, Apple green, Erythrosine.

Flow sheet for Parle-G Production

Manufacturing Process in Detail :Receiving of Raw Materials:

List of raw materials: Maida

Sugar

Skimmed Milk Powder

Hydrogenated Vegetable Oil

Chemicals

Flavouring Agents These raw materials are supplied by a numbers of suppliers. They send the raw materials according to the specifications and conditions applied by Parle. Powered materials come in bags and boxes of various sizes. Maida is supplied in tankers from where they are transferred to silos. Liquids do come stored in drums; HVO is supplied in tanks which are emptied in silos. All the raw materials are stored in raw material store or in silos and used as and when required.

For issuing the raw material, FIFO (First in First Out) system is applied. Material is issued in sequence not irregularly. Raw material is not stored more than 5-6 days.

Quality Check:

All raw materials received undergo a quality check before storage/use. These tests are conducted by the Quality Assurance Department. If the raw material is not found according to the specifications of Parle then it is rejected and sent back to the supplier. The raw materials are first checked for physical parameters like color, odor and presence of any foreign extraneous material. Then they are tested for various chemical and functional properties.

The common tests performed on materials are:

Maida:- Moisture content, Sedimentation value, water absorption, acidity & ash content, GRANULARITY.

Fat:- Melting range, moisture content, unsaponifiable matter, free fatty ACID content, PEROXIDE VALUE,IODINE VALUE.

SMP:- Moisture content, solubility and protein content, ACIDITY.

Chemicals:- %age purity.

Sugar Syrup:- Brix ,PH AND INVERSION.

Storage :-The raw materials found in accordance with the specifications are stored in the raw material store from where it is issued as and when required. The raw materials are stored to meet the requirements of next 2-3 days. The maximum storage period of various raw materials is as follows:

Raw MaterialStorage Time

Maida7 Days

Vanaspati7 Days

Sugar1 Month

SMP1.5 Months

SMBS6 Months

SBC1 Month

ABC1 Month

Salt2 Months

Finamul1.5 Months

Flavours1 Year

Maida Dumping and Shifting:-

Maida dumping is done by two methods: Automatic and Manual.

If automatic maida is fed to the plants from the silos. The maida is pneumatically transferred from the silos to the service tanks from where it is transferred to the sifter. The maida is sifted and then transferred to the maida service tank from where it is send to the mixing section.

In the manual method the maida bags are unloaded in the maida hopper from where it is transferred to the maida service tank by a screw conveyor. The following procedure is same as that of automatic maida feeding method.

The combination of method of feeding is used and adjusted in accordance with the man power available.

Sugar Grinding:The sugar bags are unloaded which is provided with a magnet which is there to remove the metal pieces present in the sugar. It is made sure that the sugar is free from moisture. This sugar is transferred to the grinder through a screw conveyor. The grinded sugar is stored in a tank provided at a bottom of the grinder. The sugar is then transferred to the service tank which sends it to the mixing section.

Pumping of Fat:Fat stored in the silos is pumped at a temperature of 450 C. The fat is mixed with finamul, which acts as an emulsifying agent. This mixture is added to the batch in a suitable quantity so as to prepare consistent dough. The finamul is also found to have anti oxidation effects on the biscuit. The mixture of fat and finamul is added to the liquid vessel of the mixing panel from where it is mixed into the dough.

MIXING SECTION:Mixing Section is the heart of baking industry. It is the section where all the raw materials of the recipe are mixed and consistent dough is prepared. If there is any problem in dough or defect found in the biscuit it is controlled by a change in recipe from the mixing section. The other functions carried in mixing section are weighing of chemicals and preparation of PFM and sugar syrup.There are three vessels for the purpose of mixing of various ingredients: powder vessel , liquid vessel and creamer. The flour and sugar are filled in powder vessel automatically. The liquid vessel has two parts one for RBD palm oil and other for the liquids like water, PFM and sugar syrup. The chemicals are added in as the manual dose to this vessel and are mixed with the liquid. This mixture is stirred for some time. These vessels are- emptied into the Stephan-mixer where it mixed by a high-speed motor for 1-1.5 minutes.MOTOR OF HIGH SPEED MIXER - 60 HP

In high-speed mixer chilled water is circulated to cool the dough in summer, which is desired to suppress excess gluten development. While in winter, Luke warm water is circulated to prevent chocking of fat.One batch is of approximately 180 kg. The major constituents of the dough are Maida, sugar, fat, and SMP. The batch must be consistent and its temperature must be controlled.After mixing dough is discharged into the hopper. Then with the help of two feed rolls and cutter dough comes on the dough conveyor.Various Temperatures at mixing section:Water23C

Sugar Syrup30C

Powders (sugar + flour)30C

HVO45C

Dough Temperature31-32C

Mixing Contributes in:1. Blending ingredients together to form a uniform mass.2. Dispersal of a solid in a liquid or liquid in a liquid.3. Dissolving solid in a liquid.4. Kneading the mass to impart the development of gluten from flour proteins in the presence of water.5. Aeration of a mass to give a lower density.6. The build up of temperature as a result of work imparted.

ROTARY SECTION:Metal Detection:Dough, after cutting, is passed through a metal detector, which is fixed just above the dough conveyor; it can detect all types of metallic materials. Ferrous,nonferrous,stainless steel. If a metallic particle is present in dough, detector produces a characteristic sound and that of dough is immediately removed from dough convey of bell manually. This is one of the Critical Control Points maintained at Parle. The metal detector is checked for its efficiency from time to time.

Moulding:Rotary moulder is used for this purpose consists of three rolls and a knife.

Three rolls are -Die roll, feed roll and rubber roll. Rotary moulding is a simple, efficient and convenient way of machining short dough. The problems of sheeting, laminating and gauging are eliminated and there is no scrap dough for recycling, which means more uniformly developed dough pieces. The system consists of three rollers installed under the dough hopper in a triangular shape. The upper two rolls (Die roll and feed rolls) consist of a heavily seated roll that pulls the dough down from the small hopper and forces it into biscuits sized impressions in the engraved roller. At the narrowest point between the two rollers, a knife scrapes any excess dough from the surface of the engraved rolls. Position of knife can be changed to get required wt. to mould. The wt. of 12 moulds should be about 78 gm. Knife clock system denotes position of knife (usually in the range of 10 to 11), leaving the biscuit impressions in the roll full of dough. Beneath the engraved roll is the third "extract" roller that is covered with thick rubber to make it resilient. This roller drives the cotton take way conveyor wrapped around it.

Pressure (2 to 2.5 kg per cm2) is applied on the engraved roller by the extract roller, causing the dough in the engravings to adhere preferentially to the cotton conveyor, which carries the dough pieces away to the baking line.

There are 31 rows present on the die roll. Each row is having 12 cups. Hence in one revolution 31 x 12 biscuits are moulded. Speed of rubber roll is more than die roll to maintain the specific length of biscuits.If the dough is extensible, it may be released from the mould between the knife and the extraction point, which reduces molding efficiently and causes dough scrap. Therefore, extensible dough should not be rotary molded.The various other parts of the rotary section are as follows:Extraction Belt:This belt is used to convey moulded dough from die roll to panning table belt. Steam is produced by heating water, in the water tank placed under the extraction belt, which softens the extraction belt (made of fibre) so that adhering force between moulded dough and extraction belt is maintained.Cross conveyor or scrap conveyor: -

It is used to remove scrap adhering to the extraction belt. Scrap falls on cross scrap conveyor belt. Scrap collected in small hopper and directly goes to the dough hopper with the help of air blower connected to the scrap hopper to dough hopper. In case scrap is found attached to the biscuit, the distance between the belts is increased so that the scrap falls between the belts.Panning Table Belt:-

This is used to carry moulded dough from extraction belt to wire-band. It can serve following functions:1. Length of moulded dough can be increased by increasing speed of panning table belt.2. For proper placing of moulded dough on the wire-band.3. Detach moulded dough from extraction belt.BAKING:Oven:Oven is one of the important part of baking industry. For baking Parle-G traveling oven used is LPG or Propane direct gas fired oven. There are 10 zones in oven, 11 exhaust fans and 2 air blowers to remove excess heat and gases from oven. Each zone has different number of burners

The oven consists of a wire band moving inside the moving tunnel from both the sides. The temperature set is different in each zone. The material to be baked is placed on the wire band, which moves at a definite speed. The baking time and speed of the wire band is adjusted according to the rpm of die roll and the temperature profile. Each of the zone is provided with a Damper which is there to remove moisture from the biscuit. The damper position can be varied from 0 (fully closed) to 8 (fully open) as per our requirement. The damper is closed in the initial zone for the maximum moisture retention and is fully open in the last zone for the maximum removal of the moisture. The weight of 12 unbaked biscuits is approximately 78g.The oven is provided with a pre heater which heats the wire band to a temperature of about 120C to remove carbon and sticking problem of biscuits.

The oven is divided into three Major parts:

Puffing Zone : Zone 1 to 3 Baking Zone : Zone 4 to 7

Coloring Zone : Zone 7 to 10

Brief description of each zone is given below:Puffing Zone (Zone 1 to 3): The leavening agents act a major role in this zone. The steam and other volatile gases do rise and increase the volume of the biscuit.The leavening agents like Ammonium Bi-carbonate and Soda do produce carbon dioxide, steam and ammonia which aerate the biscuit. This gives a porous texture by the formation of puffs in the biscuit.2 Na HC03 Na2C03+ C02+ H20NH4HCO3 NH3 + CO2 + H2O

Baking Zone (zone 3 to 7): This is the zone where the biscuits actually get baked. The temperature of this zone is between 220-320C. This is one of the CCP of Parle. The moisture content of biscuit gets reduced to 1.4 - 2.4% in this zone.Colouring Zone(zone 8 to 10): This is the zone where the colour of the biscuit is attained. The colour is achieved due to following reactions:Caramalisation*Maillard ReactionThe temperature of this reaction is less than that of the baking zone.Baking Time: 3-3.5 minutesAfter baking the moisture content of the biscuit is 1.4% to 2.4%. The weight of thebiscuit is 82.5 g(approx).

The graph of temperature of ovens is Parabolic i.e. in initial 1,2,3 zones temperature is less, then in 4,5,6 zones temperature goes to the peak point where ammonia get 100% removed and soda retains 50% in the biscuits. Later on temperature get reduced in 7,8,9,10 zones where color is developed on the biscuits. So 4,5,6 zones are critical control points.

COOLING OF BISCUITS:Biscuits coming out of the oven are too hot to be packaged, so they are transferred to a cooling band, which is on open conveyor running between the end of the oven and the wrapping machines. Cooling is also necessary for sugar rich biscuits, as they are very soft as they leave the oven and set rigid when cool. There is also an appreciable loss of moisture as the biscuits cool, and this is beneficial to their quality and shelf life.Cooling Conveyor:The cooling conveyor is made up of Convase (food grade) and biscuits are cooled naturally on the conveyor. Length of cooling conveyor should be 1.2 to 1.6 times of the oven length. An industrial metal detector is placed just above the cooling conveyor - I and at the end of cooling conveyor II and these are the critical control points of cooling section.Cooling conveyor - II is placed just below the cooling conveyor I.

It carries biscuits from cooling conveyor-I to stacker.PACKAGING SECTION:The package section consists of stacking of biscuits and then packing them in the packets of 82.5 grams and 38.5 grams 209 grams 313.5 grams. After that these packs are packed in polybags with coupons. These polybags are further packed into C-boxes. These C-boxes are sent for dispatch.

Stacking:It aligns the biscuits in rows and these rows of biscuits move with stacker table belt. Biscuits are manually sorted and lined up at the beginning of stacker. There aligned biscuits are sent to packaging machine either by auto feeding or by manual feeding. Some remaining biscuits on belt are arranged in trays and rest others collected ina drum at the end of stacker.A brush roll fitted just above stacker belt (brushes touching biscuits) to control the movement of biscuits i.e. help to come biscuits one by one.The operator at the stacker checks the biscuit quality and rejects them if they are defective.

The biscuits are checked for length, width and stack height by the quality assurance lab and if the biscuits are not found in accordance with the specification they are rejected.Packaging Machine:Parle-G is packed in two kinds of packs: 82.5 grams and 38.5 grams 209 grams 313.5 grams packets. The unit at Neemrana has well developed packing Machines. These machines automatically wrap the wrappers around the biscuits. The commonly used packing material is BOPP (Bioxyl oriented polypropylene). The printing of the packaging material is done in the printing section of the factory. After printing, the wrappers are observed in laboratory for any type of disorderness and any type of bad odour and smells. After automatically packing of wrappers around the biscuits, sealing is done with the help of roller heaters. Some heaters are used for side sealing and some are used for cross sealing. The packing machine packs the biscuit using the stack height as the major parameter.

If packaging is not proper then these packets removed manually and collected in a drum.These are then unwrapped biscuits arranged in trays manually and trays carried for repackaging.After packing the packets are sealed in poly bags and they are packed into cartoon boxes, these boxes are then sealed and batch number is printed by another machine and boxes are now ready for marketing.The number of packets in a polybag are as follows:24 packets of 82.5 g in a polybag and 6 polybags in a c-box.30 packets of 38.5 g in a polybag and 12 polybags in a c-box.

60 Packets of 209 g in a c-box.

40 Packets of 313.5 in a c-box.

DISPATCHING:The biscuits packed in a C-boxes are collected on a pallet in the B.S.R (Bounded stock room) section. These pallets are carried by a forklift. The biscuit boxes are loaded in a truck and transported to various depots situated at different locations. These depots sell these biscuits to various retailers which further sell the biscuits in the local market. The biscuits are dispatched in FIFO manner.If there is any problem found in the biscuit they are returned to the B.S.R. They are kept in the category of market complaints and immediate action is taken to improve the quality of biscuit and packaging so that there is no market complaint.HIDE & SEEK MILANO

COOKIES

Cookies are often reffered to as small sweet cakes. They are characteerised by a formula high in sugar and shortening and low in water. In UK , cookies means something softer and thicker baked good while biscuit refer to a flat and crisp baked good. In USA , cookis covers any flat, crisp, baked good.

PARLE also have the production of cookies that is HIDE & SEEK MILANO .

There are four types of varieties:

I. Milano Chocolate Chips.II. Milano Chocolate & Nut.III. Milano Butterscotch.IV. Milano Butternut.RAW MATERIALS AND INGREDIENTS

Wheat flour

Partially hydrogenated edible vegetable oil

Sugar

Butter

Inverted syrup

Liquid glucose

Milk solids

Leavening agents

Salt

Emulsifier

Antioxidents

GENERAL PRODUCT CHARACTERISTICS

Variety : Soft Dough , wire cut or knife cut.

Size : 65 mm x 12 mm thick.

Design : Round with disorted top and flat.

Shape : Round.

Packet size : 65 gm, 135 gm.

Bite : Crispy.

1) Milano Chocolate Chips :

Special Ing. Chocolate Chips / cocoa solids.

Taste Sweet , rich chocolate.

Colour Brown.

2) Milano Chocolate & Nut :

Special Ing. Chocolate Chips , Cashew Bit & Artificial Chocolate & Vanilla flavours.

Taste Sweet , rich chocolate.

Colors Brown.

3) Milano Butterscotch :

Special Ing. Butterscotch pieces, Artificial Butterscotch flavours.

Taste: rich Butterscotch.

Colors Golden to light Brown.

4) Milano Butternut :

Special Ing. Cashew bits , Artificial Butter flavours.

Taste rich Butter.

Colour Golden to light Brown. GOLDEN ARC

Fruit Jam filled bar made by extruding dough for the jacket and jam for the filling through concentric orifices in a bar press machine.

Two hoppers and two sets of forcing rollers (or screw extruders) are required to feed yhe dies.

Fruit paste is led through the dough hopper portion to its designated orifice by tubes or chutes.

The extruder must be adjusted to deliver a design of dough that is moving at the same speed as the oven band so as to avoid streching , wrinkling or breaking the dough strip.

These bars are cut into individual cookies when they come out of oven.

Special Ing. Fruit paste, starch, maltodextrin, soya lecithin, citric acid colour and flavours.

Variety Exotic pineapple/ Orange flavoured rolls.

Size 35 mm x 34 mm

Taste Sweet & Sour.

Design Cubical, flat roll.

Colour Light Brown.

Bite soft.

Shape Recangular.

DUALTEX EXTRUDER It is specially designed to produce the new generation of filled bars, filling of fruit jam & sweet and savoury creams can be handled.

Extruders vary in complexity from simple equipment consisting of a hopper with feed rolls that press dough through adjustable slits to very complicated devices that extrude deposit cookie batters through orifices moving in predetermined patterns.

The most common type of machine consists of a hopper with one or more feed rolls to force dough through a number of tubes usually called die cups.

These die may have orifices of different shapes squares, round, oval, scalloped etc.

In wire cut machines, discs are sliced from the continuously extruded cylinder of dough and allowed to drop onto the oven band or transfer belt.

A key hygiene feature is the ability to open up the clam shell rolls for easy cleaning.

It is chosen for Highest Output, Highest Accuracy, Widest Product range, Greatest Productivity, Precise Weight control, Essy to Operate & Clean, and Minimum Downtime.

study of various kinds of defects of biscuitsThere are various kinds of defects which are encountered during the production of biscuits. These defects may arise due to any kind of disproportion in the dough mixture or due to any problem at the rotary section or at the oven. The food technologist plays an important role in troubleshooting of these defects. These defects are checked by changing the recipe, variety and quantity of various ingredients or by making changes in machine settings at the rotary or oven level. The experience of the food technologist plays a very important role in the troubleshooting of the various kinds of biscuits to reduce the rejected biscuits. One has to make the best use of the ingredients and technology available as well as minimize wastage to the lowest possible value. The major defects observed in Parle-G are as follows: Spreading of biscuits

Shrinkage of biscuits

Less stack height Blisters

Dark biscuits Pale biscuits Hard bite of biscuits

Black specks Poor Finishing of biscuits

Scrap in biscuitsDISCUSSION OF BISCUIT DEFECTS IN DETAIL1. Spreading Of Biscuits:Many times it is seen that the baked biscuits are of width beyond the tolerable limit. This is known as spreading of biscuits. The major cause is soft or loose dough. The various causes and the remedies are as follows:Sr. No.CausesSolution

1.Weak flour being usedUse strong flour or try blending

2.Insufficient mixing timeAdjust mixing time

3.Baking profile not appropriateIncrease bottom temp. In initial zones

4.Too soft doughAdjust quantity of water

5.Use of excess sugarUse less sugar

6.Use of excessive ammonium bi carbonateUse less ammonium bi carbonate.

7.Sugar powder too fineUse coarser sugar powder

2. Shrinkage of Biscuits:Sometimes it is seen that the width of biscuit is less than acceptable. This shrinkage of biscuits. This is observed due to hard and dry dough or due to improper setting at rotary section.Sr.No.CausesSolution

1.Flour being used is strongUse weak flour or try blending

2.Higher mixing timeAdjust mixing time

3.High dough temperatureUse cold water for mixing

4.Too dry a doughIncrease water in the recipe

5.Incorrect rubber roller speedAdjust the rubber roller speed

6.Less fatIncrease fat quantity

7.Less sugarIncrease sugar quantity

3. Less Stack Height:Stack height is one of the major parameters of biscuit quality. It should be ac the specifications. The stack height of 15 biscuits of Parle-G is 114 2 mm. If the height is less than 112 it is a major concern and an immediate action is to be taken to reduce wastage.S. No.CausesSolution

1.The flour used is strongUse weak flour or try blending

2.Less quantity of A.B.CIncrease A.B.C in recipe

3.Less quantity of waterIncrease water

4.Use of old doughUse old dough in small quantities

5.Excess pressure of rubber rollReduce roll pressure

6.Improper knife settingAdjust knife settings

7.More S.M.B.SReduce quantity of S.M.B.S

8High dough temperatureUse cold water and maintain dough temp.

9.High sugar syrup temperatureReduce temperature of syrup

10.More mixing timeAdjust mixing time

4. Problem Of Blisters:A blister is a lump formed on the surface of the biscuit. It may be a chemical blister or a heat blister. The various cause and remedies of blister formation are discussed below:

Causes: If the batch is hard. If ammonia is more. If old dough is not properly fixed. If the dough temp is high. If the mixing time is more.1.Less water.Maintain water quantity as per Maida quality

2.Less ABC/SBC.Control on ABC/SBC quantity

3.Rubber roller pressure high.Maintain rubber roller presser

4.Maida Quality.Check Maida quality as per standard

5.High gluten Maida.We can not accept More higher gluten Maida

6.No proper water T.D.S. (70-80)Proper checking of water T.D.S.

7.Excess mixing time.First check Maida quality and then give proper mixing time

8.Less Soda.Proper guidance gives to teammates who include soda in batch and proper control.

9.Starting temperature not proper in oven (puffing zone).Maintain oven temperature in first three zone

10.Dough temperature.Check dough temperature and make check list

11.Less Fat.Proper guidance give to team-mates who is include soda in batch and proper control.

12.Raw material temperature.Maintain raw material temperature

13.More standing time of dough.Not give more standing time

8. Black Specks:The black specks may be due to the carbon particles from the oven or may be due SMP or caramalisation of sugar particles. These particles give an unattractive appearance to the biscuits. The various causes and troubleshooting methods are discussed as follows:S. No.CauseRemedy

1.Un-cleaned wire bandClan the wire band regularly

2.Carbon particles falling in the ovenOven must be cleaned and decarbonized regularly

3.Presence of un dissolved SMPSMP must be dispersed well and shouldbe free of lumps '

9. Poor finishing of biscuits:

This kind of problem occurs due to the chocking of rotary moulder or due to damage of cups of the moulder. moulder must be cleaned properly to avoid choking. in case of damage of cup it must be repaired or die rol must be changed. the other cause of the problem is worn out rubber roll. this problem may also be due to inconsistent dough or if the dough is very oily. This can be avoided by using proper quantity of ghee.10. Scrap in biscuits:Sometimes it is seen that the scrap at rotary gets attached to the biscuit causing deterioration in its shape & giving it an unattractive appearance. This problem can be solved by increasing gaps between the belts at cross conveyor.TESTING PROCEDURES FOR Wheat Flour (Maida)

1a. DETERMINATION OF MOISTUREPROCEDURE

Weigh accurately 5 g sample of maida in a dish that is previously dried in an electric oven and weighed. Place the dish in oven maintained at 1100C for one hour. Cool the dish in the desiccators and weigh it accurately. The difference between the initial weight and the final weight is calculated.

CALCULATION

Moisture (% by wt.) = 100 X (W1 W2)

W1 - W

W1 = mass in gram of the dish with the material before drying

W2 = mass in gram of the dish with the material after drying

W = mass in gram of the empty dish

1b. DETERMINATION OF TOTAL ASH

PRINCIPLE: The ash of a foodstuff is the inorganic residue remaining after the organic matter has been burnt away. When a high ash figure suggests the presence of an adulterant, it is often advisable to determine the acid insoluble ash also.

PROCEDURE

Weigh accurately 5 g of above homogenized sample in a tarred, clean, dry & preweighed porcelain dish / Silica dish / Platinum Dish.

Ignite the sample in the dish with the flame of a suitable burner (Oxidizing flame) for about one hour.

Complete ignition, by keeping it in a muffle furnace at 600 +/- 20 0 C until grey ash results.

Cool in a desiccators & weigh.

Repeat the process till constant weight.

Note the final weight.CALCULATIONS

% Ash = (W2 W1) x 100 W

Where,

W2 = Final wt. of dish + Ash

W1 = Wt. of dish

W = Wt. of sample

% Ash on wet basis X 100% Ash on Dry Basis = ----------------------------------------

100 Moisture of Sample

1c. DETERMINATION OF ACID INSOLUBLE ASH

PRINCIPLE: The acid insoluble ash is a measure of the sandy matter present in the sample. The ash is treated with concentrated HCl so that all minerals except silica remains insoluble, which can be further, calculated.

REAGENTS:

5 N HCl: Dilute 425 ml (182.3 g) of hydrochloric acid with water to make 1000 ml.

PROCEDURE

Dissolve the resultant ash (ash earlier obtained) in a 25 ml of 5 N HCl with the aid of heat.

Allow cooling & filtering the contents of the dish through Whatmann filter paper no. 42.

Wash the filter paper with hot water until washings are free from the acid (check with the help of pH paper).

Return the filter paper & the residue to the Porcelain dish / Platinum dish / Silica dish.

Keep in a muffle furnace at about 600 +/- 20 0 C for 2 hrs.

Cool the dish in a dessicator & weigh.

Repeat the process till constant weight is obtained.

CALCULATIONS

% Acid insoluble ash = (W2 W1) x 100

W

Where,

W2 = Final wt. of dish + sample

W1 = Wt. of dish

W = Wt. of Sample.

% Acid Insoluble Ash X 100% Acid Insoluble Ash on Dry Basis = ----------------------------------------

100 Moisture of Sample

1d. DETERMINATION OF GLUTEN

PRINCIPLE

The strength of flour depends upon both the amount and the physical qualities of the gluten. Crude gluten obtained in this way contains albumin, globulin, glutenin, gliadin and proteose.

PROCEDURE

Take 15 g of maida and make dough by adding about 7-8 ml of water. Allow it to stand in water for 1 hour. Then wash down the dough by squeezing in the fingers in the running water. Wash the dough until the starch is completely washed away and water squeezed out runs quite clear. Squeeze out the water from the gluten as dry as possible. Break the gluten ball into tiny pieces and dry in the oven. Calculate the % gluten as follows.CALCULATIONS

(W2 W1) X 100

% Gluten on (Wet basis) = ------------------------ = A

W

Where,

W1 = Weight of empty dish

W2 = Weight of the dish + dry Gluten

W = Weight of Sample

100 X A

Gluten on dry weight basis = ---------------

(100 M)

Where,

M = Moisture content of the flour

1e. DETERMINATION OF GRANULARITYPROCEDURE

Transfer about 100 g of material to a hand silk sieve of 180 microns & sieve for 2 minutes. Brush the upper surface of the sieve & sieve again for one minute. The material is satisfactory if no residue remains on the sieve.

1f. DETERMINATION OF SEDIMENTATION VALUE

PRINCIPLE: The volume of sediment formed when flour is suspended in water and treated with lactic acid consisting of swollen gluten and occluded starch is the sedimentation value.

APPARATUS: Sedimentation Shaker, Muhlenbau cylinder (height of graduation from 0-100 ml should be 185 mm)REAGENTS: Isopropyl alcohol (99- 100 %), AR

Lactic acid stock solution: Dilute 250 ml of 85 % lactic acid (AR) to 1 lit with water. Reflux diluted acid for 6 hrs without loss of volume.

IPA- Lactic acid reagent: Mix thoroughly 180 ml lactic acid stock soln., 200 ml isopropyl alcohol and water to make 1 lit. Let it stand 48 hr. before using.

Bromophenol blue indicator: Water containing 4 mg of bromophenol blue per liter.

PROCEDURE

Sieve maida through 100-mesh sieve. Place 3.2 g of the sieved flour in the cylinder. Add 50 ml water containing bromophenol blue. Mix thoroughly flour & water by moving the cylinder horizontally 12 times vigorously. Start the timer & place the cylinder on shaker for 5 min. Remove the cylinder & add 25 ml of isopropyl alcohol-lactic acid reagent. Place the cylinder again on shaker for 5 min. Remove from shaker & keep the cylinder in upright position & let stand exactly 5 min. At the end of 5 minute read the volume in ml of sediment in cylinder.

1g. DETERMINATION OF ALCOHOLIC ACIDITY PRINCIPLEFlours when stored for longer period, undergoes various types of deterioration, which in turn gives high values for alcoholic acidity. Hence, alcoholic acidity is an index of deterioration of flour during storage. Alcoholic acidity therefore refers to the combined acidity as we get by

Hydrolysis of fats by lipases into free fatty acids.

Hydrolysis of proteins into amino acids by proteolytic enzymes.

Acidity due to the presence of certain acid salts etc.

REAGENTS90 % Alcohol: Dilute 700 ml of 95 % ethyl alcohol to 740 ml with Distilled water.

0.1N NaOH: 4 g of Analar Sodium Hydroxide per 1000 ml of distilled water & then standardize against Potassium hydrogen phthalate as follows:

Transfer 0.5 g of potassium bipthalate, previously dried at 105 degrees for 2 hrs and accurately weighed to a flask & dissolve it in 75 ml of carbon dioxide free water. Add 2 drops of phenolphthalein indicator and titrate against NaOH soln to a permanent pink colour. Each 204.2 mg of potassium bipthalate is equivalent to 1 ml of 0.1 N NaOH.

Phenolphthalein TS: Dissolve 1 g of phenolphthalein in 100 ml of alcohol.

PROCEDUREWeigh 5 g of sample into 250 ml of stopper conical flask. Add 50 ml of 90 % ethyl alcohol (neutralized with NaOH using phenolphthalein as indicator). Shake the contents very well & keep the flask for 24 hrs. Filter the contents through filter paper & pipette out 10 ml of filtrate for the titration. Titrate it against 0.1 N NaOH to a permanent pink colour.

CALCULATION Alcoholic acidity (as H2SO4) = 24.52 X A X N % by weight

W

N = Normality of NaOH.

W = Weight in g of the sample.

A = Volume in ml. of 0.1 N NaOH

ANALYSIS OF VANASPATI

2a. COLOUR: The color of Vanaspati accepted is yellow.2b. ODOUR: Vanaspati is heated to 70 0 C & then odour is checked. Vanaspati should be free from foreign matter & free from any odd odour.

2c. TASTE: Vanaspati should have a characteristic taste.2d. DETERMINATION OF PEROXIDE VALUE

Scope: Applicable to all normal fats & oils including margarine.

Definition: Peroxide value is a measure of the peroxides contained in a sample of fat, expressed as mill equivalents of peroxide per 1000 g of the material.

Apparatus: Conical flask with stopper (250 ml), Burette 50 ml

Reagents1. Acetic acid Chloroform Solution: Mix 3 parts by volume of glacial acetic acid with two parts by volume of chloroform.

2. Potassium Iodide Solution: Prepare saturated solution of Potassium iodide in freshly boiled distilled water. Store in the dark. (Freshly prepared)

3. Sodium Thiosulphate Solution (0.01 N): dissolve about 1.581 g of sodium thiosulphate per 1000 ml). Standardize as follows

Weigh accurately about 21 mg of potassium dichromate previously dried at 120 0 C for 4 hr. and dissolve it in 100 ml of water in a 500 ml glass stopper flask. Swirl to dissolve the sample & remove the stopper, and quickly add 3 g of KI and 5 ml of HCl. Let stand in dark for 10 mins. Rinse the stopper and inner wall of flask with water and titrate the liberated iodine with sodium thiosulphate until the solution is faint yellow in colour. Add starch T.S. and continue the titration to the discharge of the blue colour, calculate the normality as follows,

g of K2Cr2O7 X 1000

Normality = -------------------------------------------

ml of Na2S2O3 X 49.032

4. Starch Solution (1 %): Dissolve 5 g of starch in 500 ml of hot distilled water. Cool & filter. (Freshly Prepared)

ProcedureWeigh 5.0 +/- 0.05 g of sample in a 250 ml Stoppered conical flask. Add 30 ml of acetic acid chloroform solution. Swirl the flask until the sample is dissolved. Add 0.5 ml of saturated potassium iodide solution. Allow the solution to stand exactly for a minute with occasional shaking. Continue titration till the yellow colour almost disappears. Add 0.5 ml of starch solution & continue titration till the blue colour just disappears.

Conduct a blank determination of the reagents.

Calculations

Peroxide Value = (S B) x N x 1000

Wt. of the sampleWhere,

B = Titration of blank, ml

S = Titration of sample, ml

N = Normality of Sodium thiosulphate solution.

2e. Acid Value (Free Fatty Acids)

Scope: Applicable to all normal oils & fats.

Definition: Acid value of an oil/Fat is defined as the number of milligram of potassium Hydroxide/Sodium hydroxide required to neutralize the free fatty acids present in one gram of oil under the prescribed conditions.

ReagentsEthyl Alcohol (Rectified Spirit): 95 % of volume, neutralized using phenolphthalein indicator.

Phenolphthalein TS: Dissolve 1 g of phenolphthalein in 100 ml of ethyl alcohol.

Standard Sodium Hydroxide (0.1 N): Dissolve 4 g of sodium hydroxide in 1 Lit water & standardize using potassium hydrogen phthalate as follows:

Transfer 0.5 g of potassium bipthalate, previously dried at 105 degrees for 2 hrs and accurately weighed to a flask & dissolve it in 75 ml of carbon dioxide free water. Add 2 drops of phenolphthalein indicator and titrate against NaOH soln to a permanent pink colour. Each 204.2 mg of potassium bipthalate is equivalent to 1 ml of 0.1 N NaOH.

Procedure

Weigh about 20 g of well-mixed sample into a 250 ml conical flask. Add 50 ml of neutral ethyl alcohol & 1 ml of phenolphthalein indicator solution. Boil the mixture for about 5 minutes in a water bath & titrate while hot with 0.1N NaOH, shaking vigorously during titration. Endpoint is from colorless to light pink (persisting for 30 sec.)

Calculations

Acid Value = 56.1X V X N

W

Where, V= Volume in ml of 0.1 N NaOH

W= Weight in g of sample

N= Normality of NaOH

0.0282 X 100 X Reading

F.F.A. = ----------------------------------

Weight of sample

Acid Value

F.F.A. (as oleic acid) = ------------------

2

2f. Iodine Value (Wijis Method)Scope: Applicable to all normal oils & fats.Definition: Iodine value of oil is defined as the number of grams of Iodine absorbed by 100 g of the oil when determined using Wijs solution.

Apparatus

Glass Stopper conical flask 250 ml

Measuring Cylinder (50 ml)

Bulb pipette (25 ml)

Reagents

Glacial Acetic Acid: AR GradeCarbon Tetra chloride: GR Grade

Iodine Monochloride Carefully break open 1X 50 g ampoule of ICl and pour into 155 ml of Glacial acetic acid. Mix well & store in a well Stoppered amber colored bottle. This is the stock solution. Dilute 50 ml of Stock solution to 1000 ml by using Glacial Acetic Acid. Mix well & store in a well Stoppered clean & amber colour glass bottle. This is the solution to be used for determination of Iodine value.

Potassium Iodide solution (10 %): Dissolve 10 g of Potassium Iodide AR in 90 ml of water. Store in clean and dry amber colored bottle.

0.1N Sodium Thiosulphate: dissolve about 15.81 g of sodium thiosulphate per 1000 ml). Standardize as follows:

Weigh accurately about 210 mg of potassium dichromate previously dried at 120 0 C for 4 hr. and dissolve it in 100 ml of water in a 500 ml glass stopper flask. Swirl to dissolve the sample & remove the stopper, and quickly add 3 g of KI and 5 ml of HCl. Let stand in dark for 10 mins. Rinse the stopper and inner wall of flask with water and titrate the liberated iodine with sodium thiosulphate until the solution is faint yellow in colour. Add starch T.S. and continue the titration to the discharge of the blue colour, calculate the normality as follows,

gm of K2Cr2O7 X 1000

Normality = ------------------------------------

ml of Na2S2O3 X 49.032

Starch Indicator: Dissolve 5 g Starch in 500 ml of hot distilled water, cool and filter

(Freshly Prepared)

THEORY :

When oil is treated with excess of Wijs solution i.e. ICl, some ICl gets absorbed. This ICl adds on to the double bonds present in the oil. Unused ICl reacts with KI soln. & liberates an equivalent amt. of Iodine which is titrated against std. Sodium Thiosulphate soln. Iodine value is a measure of unsaturation of oils & fats.

PROCEDURE

Weigh accurately the quantity of filtered sample mentioned in individual monograph in a clean dry 500 ml iodine value flask containing 20 ml of Carbon tetra chloride. Gently agitate to effect solution. Add 20 ml of Iodine Monochloride solution immediately (by pipette) Stopper the flask using the quick moistened with Potassium Iodide solution & keep in the dark for 30 mins. At the end of the period remove the flask, add 15 ml of 10 % Potassium Iodide solution & 100 ml of water washing down the stopper & titrate with 0.1 N Sodium Thiosulphate using 1 2 ml of Starch solution as indicator towards the end of the titration. Vigorous shaking is necessary during & towards the end of the titration. Carry out a blank determination excluding the sample. Calculate I.V. or % Iodine absorption of the sample using the relation.

CALCULATIONS

1 ml of 0.1 N Sodium Thiosulphate = 0.01269 g of Iodine

Iodine Value = 12.69 x N x (B.R. S.R.)

Wt. of sample

N = Normality of Sodium Thiosulphate.

2 h. DETERMINATION OF MELTING POINT ( Slip Melting Point )

Scope: Oils & fats are chiefly mixtures of glycerides. They do not exhibit either a definite or a sharp melting point. Therefore, the term M.P. does not imply the same characteristics that it does with pure crystalline substances.

Capillary Slip Method

Apparatus

Melting point tubes thin walled, uniformly bored capillary glass tubes at both ends & with the following dimensions:

Length: 50 60 mm

Inside diameter: 0.8 1.1 mm

Outside diameter: 1.2 1.5 mm

Thermometer

Beaker

Heat Source

Procedure

Melt the sample & filter it through a filter paper. Insert a clean melting point tube into the molten sample product so that a column of the material, about 10 mm long, is forced into the tube. Cautiously fuse one end of the tube in a small flame, taking care not to burn the fat. While the fat is still in the liquid state, transfer to a refrigerator & hold at 4- 10 0 C overnight (about 16 hrs.). Remove the tube from refrigerator, & attach with a rubber band to the thermometer so that the lower end of the melting point tube is even with the bottom of the bulb of the thermometer. Suspend the thermometer in a large test tube & immerse it in a beaker filled with liquid paraffin. Apply the heat to the beaker so as to increase the bath temp. at the rate of about 0.50 C per minute. As fats usually pass through an opalescent stage before melting completely, the heating is continued until the liquid in the tube is completely clear through out. Observe the temperature at which the liquid becomes clear. Report the average of 2 such separate readings, i.e. the M.P. for the fat.

ANALYSIS OF SKIMMED MILK POWDER

4a. FLAVOUR & ODOUR: It shall be pleasant and clean and free from off Flavour.

4b.COLOUR: The colour of SMP accepted is slightly white to creamy white in

Colour.

4c. MOISTURE PROCEDURE

Weigh about 5- 10 g of Sample in Aluminium dish & keep it in air oven for 1 & half hour at a temperature of 105 110 o C. Then remove the dish from the oven & cool it in desiccators. After cooling, weigh the dish again & note the reading. Continue the heating, till we get the constant weight of the dish up to 2 mg difference.

CALCULATION

Moisture % = (W1 W2) x 100

(W1 W)

W1 = Weight of dish + sampleW2 = Weight of dish + sample after dryingW = Weight of empty dish

4d. TITRATABLE ACIDITY

PROCEDURE: Weigh about 5 g. of sample in a beaker & dilute it to 100 ml in a volumetric flask. Transfer 10 ml of the solution into the flask & titrate it against 0.1 N NaOH. Indicator is phenolphthalein.CALCULATIONS:

9 x N NaOH x B.R. x 10Acidity in terms of lactic acid = -------------------------------------------

Weight of Sample

4e. PROTEIN

Protein can be determined by kjehldahls method. The weight of the sample to be taken is 0.5 g.PRINCIPLE:

Kjeldahls method for determining total nitrogen involves first heating with conc. Sulfuric acid. The reaction rate is accelerated by adding sodium sulphate to raise the boiling point. The catalyst used is copper sulphate. The oxidation causes the nitrogen to be converted to ammonium sulphate. After making alkaline with conc. NaOH, the liberated ammonia is distilled into HCl.

The protein content is obtained by multiplying total nitrogen by an empirical factor.

REAGENTS:

Conc. Sulphuric acid

Copper Sulphate ( LR )

Sodium Sulphate ( LR )

Granulated Zinc

0.1 N HCI: 3.646 g conc. HCl per 1000 ml of distilled water & then standardize as follows:

Accurately weigh about 0.15 g of primary standard anhydrous sodium carbonate, that has been heated at a temp of 270 degrees for 1 hr. Dissolve it in 100 ml of water and add 2 drops of methyl red TS. Titrate with HCl to faint pink colour. Heat the solution to boiling and continue the titration until the pink colour doesnt disappear. Each 52.99 mg of sodium carbonate is equivalent to 1 ml of 0.1 N HCl.

0.1 N NaOH: 4 g of Analar Sodium Hydroxide per 1000 ml of distilled water & then standardize as follows:

Transfer 0.5 g of potassium bipthalate, previously dried at 105 degrees for 2 hrs. and accurately weighed to a flask & dissolve it in 75 ml of carbon dioxide free water. Add 2 drops of phenolphthalein indicator and titrate against NaOH soln to a permanent pink colour. Each 204.2 mg of potassium bipthalate is equivalent to 1 ml of 0.1 N NaOH.

45 % NaOH: 45 g NaOH in 100 ml of D/ W

Methyl red indicator: 0.1 g of powder in 100 ml of alcohol.

Procedure:Weigh accurately about 0.5 g. of sample & transfer to a Kjeldahls flask. Add 0.3 g. of CuSO4 and 10 g. of Na2SO4 to the flask. Add 25 ml of conc. H2SO4 and heat the flask gently in an inclined position till the clear soln. is obtained. Then heat the flask on a high flame for 3 hrs. Then cool the digestion mixture to the room temp. Wash the digest into the distilling flask with D/W. Arrange the distillation assembly. To the receiving flask add 50 ml. of 0.1 N HCI with 2- 4 drops of methyl red indicator. Connect the distillation apparatus with the delivery tube dipping in the HCI solution. To the distillation flask add Zn metal pieces. Then carefully add digestion mixture to the flask. Rinse it with water. Add 90 ml of 45% NaOH soln. to it. Add sufficient water to the flask. Check whether the assembly is airtight. Start the water flow through the condenser. Start heating the soln. Distill the liberated NH3 into HCl soln. Continue the heating till thrice the initial vol. of HCI in the receiving flask is obtained. Open the tap & wash down the condenser & the delivery tube into the receiver. Now put off the burner. Titrate the distillate with 0.1 N NaOH till pale yellow colour is obtained. Perform the blank.

Calculations:

(B S) X 1.4 X normality of 0.1N NaOH% Nitrogen = ------------------------------------------------------------

wt. of the sample

% Protein = % Nitrogen X Empirical factor

Empirical Factor: 6.38ANALYSIS OF SALT6a. COLOUR

The iodized salt should be white in colour, crystalline solid, free from visible contamination with clay, grit, other extraneous adulterants & impurities.

6b. MOISTUREWeigh about 5 10 g of Iodized salt in Aluminium dish & keep the same in air oven for 2 hrs. At a temperature of 110 0 C. Remove the dish from the oven & cool it in a desiccators. After cooling, weigh it again & note the reading. Keep the dish again in the oven, till we get the constant wt. of the dish up to 2 mg difference.

Moisture % = (W1 W2) x 100

(W1 W)

W1 = Wt. of dish with sample

W2 = Wt. of dish with sample after drying

W = Wt. of empty dish.

6d. PURITY TEST

REAGENTS

0.1 N Silver Nitrate

16.99 g of silver Nitrate dissolved in 1000 ml of water.

5 % of K2CrO45 g of Potassium Dichromate dissolved to 100 ml

PROCEDURE

Weigh accurately about 0.25 g of the salt sample previously. Dried at 1100C for 4 hrs. & dissolve it in 50 ml of water. Add 2 ml of Potassium Chromate ( 5 % of K2CrO4 in water ) & titrate with 0.1 N Silver Nitrate until orange brown colour persists for 30 seconds.

CALCULATIONS

ml of 0.1 N AgNO3 x 0.585

% NaCl = -------------------------------------------

Weight of sample

ANALYSIS OF AMMONIUIM BICARONATE

Description: White crystals or a crystalline powder having a slight odour of ammonia .At a temperature of 60 0 or above it volatizes rapidly, dissociating into ammonia, carbon dioxide, & water, but at room temperature it is quite stable. One g dissolves in about 6 ml of water. It is insoluble in alcohol.

7a. PURITY

Reagents

Methyl Orange TS

Dissolve 100 mg of methyl orange in 100 ml of water, & filter if necessary.

1N Sulphuric acid

Dilute 30 ml (49.04 g) of Sulphuric acid to 1000 ml. and standardize as follows,

Standardization: Weigh about 1.5 g primary std anhydrous sodium carbonate, Na2CO3 that has been heated at a temp of about 270 degrees for 1 hr. Dissolve it in 100 ml of water and add 2 drops of methyl red TS. Add the acid slowly with constant stirring until the solution becomes faintly pink. Heat t6he solution to boiling, and continue the titration until the faint pink colour is no longer affected by boiling. Each 52.99 mg of sodium carbonate is equivalent to 1 ml of 1 N H2SO4Procedure

Weigh accurately about 3 g, dissolve it in 40 ml of water, add methyl orange TS, & titrate with 1 N sulfuric acid. Each ml of 1 N sulfuric acid is equivalent to 79.06 mg of Ammonium Bicarbonate.

ANALYSIS OF SODIUM BICARBONATE

Description: A white crystalline powder. It is stable in dry air, but slowly decomposes in moist air. Its solutions, when freshly prepared with cold water without shaking, are alkaline to litmus. The alkalinity increases as the solutions stand, is agitated, or is heated. One g dissolves in 10 ml of water. It is insoluble in alcohol.PURITY

Reagents

1 N Sulphuric acid

Dissolve 30 ml (49.04 g) of Sulphuric acid to 1000 ml and standardize as follows,

Standardization:

Weigh about 1.5 g primary std anhydrous sodium carbonate, Na2CO3 that has been heated at a temp of about 270 degrees for 1 hr. Dissolve it in 100 ml of water and add 2 drops of methyl red TS. Add the acid slowly with constant stirring until the solution becomes faintly pink. Heat the solution to boiling, and continue the titration until the faint pink colour is no longer affected by boiling. Each 52.99 mg of sodium carbonate is equivalent to 1 ml of 1 N H2SO4Methyl orange TS

Dissolve 100 mg of Methyl Orange in 100 ml of water , & filter if necessary.

Procedure

Weigh accurately about 3 g, previously dried over silica gel for 4 h, dissolve it in 25 ml of water, add methyl orange TS, & titrate with 1 N Sulphuric acid. Each ml of 1 N Sulfuric acid is equivalent to 84.01 mg of Sodium Bicarbonate.

ANALYSIS OF INVERT SYRUP

Colour

Colour of the syrup should be golden yellow

Odour

Odour should be sweetish

pH

Prepare 10 % solution and determine pH by suitable pH meter

TOTAL SOLIDS % BY MASS (Brix)

Total solid content is checked by Abbey Refractometer. The sample is evenly spread on the prism of refractometer & the line of demarcation of the sample on the screen is adjusted by revolving the knob of eye piece so that the line of demarcation comes exactly on the cross section marked on the refractometer screen. The corresponding reading of the total solid content in percent is read marked below in the refractometer screen.

15c. INVERSION: This is done by Lane & Eynons method.

PRINCIPLESugars containing potential reducing groups such as free aldehydes & ketonic groups can be oxidized quantitatively by heavy metal salts under suitable conditions. In this method Cupric ions are used to oxidize reducing sugars. Red Cuprous Oxide precipitate is formed. However the formation of reduced precipitate cannot be used to judge the endpoint of titration accurately. A dye methylene blue is added near the endpoint. This blue dye is converted into colorless leucobase by reducing sugars, thus enabling accurate judgment of endpoint.

REACTIONS2C4H4O6NaK + 2CuSO4 ( 2C4H4O6Cu + Na2SO4 + K2SO4C4H4O6Cu + 2NaOH ( Cu (OH) 2 + C4H4O6Na2Cu (OH) 2 ( CuO + H2O

2CuO + (- CHO) ( Cu2O ( + (-COOH)

While aldehydes are converted into corresponding acids, keto sugars are oxidized & broken down to smaller fragments. Since leucobase of methylene blue is rapidly oxidized by air, it is necessary to exclude air. This is accomplished by performing the titration while the solution being analyzed by boiling the steam produced skips out in the air.

REAGENTS

Fehlings Solution A

Fehlings Solution B

Methylene Blue Indicator

Fehlings factor = B.R. in ml. x Sample wt. in g. x dilution factorPROCEDURE

Weigh about 2 g of sample in 100-ml. beakers & dissolve weighed quantity of liquid glucose with 30 40 ml of water. Warm the above solution slightly, if necessary. Transfer the above solution to 100 ml volumetric flask. Make volume upto the mark in volumetric flask & shake the flask well. Subsequently pipette out Fehlings Solution A & Solution B ( 5 ml each) in a 250 ml conical flask. Fill the burette with solution of liquid glucose & transfer about 10 15 ml in the 250 ml conical flask filled with Fehlings soln. A & B. Warm the flask, by keeping hot on a hot plate & continue to boil. Go on adding the burette solution to get slight brick red colour. Add about 0.2 ml of methylene blue indicator & continue the titration so that the endpoint reaches from blue to brick red. Note down the burette reading.

CALCULATION

Factor of fehling Solution x 100 INVERSION = --------------------------------------------------

Weight of Sample x total solids x B.R.

ANALYSIS OF WATER

22a.TOTAL HARDNESS

REAGENTS

Total Hardness Indicator Tablets

Ammonia Ammonium Chloride Solution: Dissolve 67.5 g of Ammonium Chloride in water & add 570 ml of Ammonium Hydroxide (28 % Liquor Ammonia) & dilute to 1000 ml with distilled water.

0.02 N EDTA: Dissolve 3.72 g of Disodium Ethylenediamine tetra acetate (E.D.T.A.) per 1000 ml of distilled water.

Standardization

HCl (TS): Prepare by diluting 226 ml of HCl (36 %) with sufficient water to make 1000 ml.

NaOH (TS): Dissolve 4.3 g of Sodium Hydroxide in water to make 100 ml.

Weigh 200 mg of chelometric of Calcium carbonate & transfer to 500 ml beaker, add 10 ml of distilled water & swirl to form slurry. Cover the beaker with a watch glass & add 2 ml diluted HCl (TS) from a pipette & swirl to dissolve the contents of beaker. Wash down the sides of beaker with distilled water & dilute to 100 ml. Fill the burette with EDTA. Add about 30 ml to the beaker of Calcium Carbonate with continuous stirring. Add 15 ml NaOH (TS) and 300 mg of Hydroxy Naphthol blue indicator & continue the titration till blue endpoint.

W

Molarity = ---------------

100.09 X V

W = weight of Calcium Carbonate

V = Volume of EDTA in ml.

PROCEDURE

Take 100 ml of homogenized sample, add to it one tablet of Total Hardness Indicator & 2 ml of Ammonia Ammonium Chloride Solution to it. Shake well. Titrate with 0.02 N Standard EDTA solutions. Endpoint is from pink to blue.CALCULATIONS

1000 X V1

Total Hardness (as Calcium Carbonate) mg / lit. = -------------

V2

V1 = Volume of Standard EDTA solution.

V2 = Volume of Sample taken.

22c. pH

Determine the pH of Water by Ph meter which is previously standardized with pH buffer solutions

22d. DETERMINATION OF FREE CHLORINE

To 100 ml of water sample add 1ml of Chlorotex reagent. Shake it well & match the colour with the strip provided with the reagent.

ANALYSIS OF FLAVOURS

33a. Odour

The odour of the flavour should be characteristic. The Organoleptic analysis is most important.

33b. pH

Calibrate the pH meter with standard 4 & 7 pH solutions & then measure the pH of the flavour directly.

33c. Specific gravity

Weigh a clean, dry 25 ml capacity Specific gravity bottle with stopper (Wash the bottle, dry with acetone if required & place it in oven. Let it cool in desiccators. Stopper the bottle & then weigh it (W1). Then fills the bottle with distills water, stopper it & again weigh it (W2). Again wash the bottle as above & fill it with given flavour, stopper it & weigh the bottle (W3). All the weights should be measured at same temp. (Ideally 250C)

Calculations

W3-W1

Specific gravity = -------------

W2-W1

Packaging Material-

Packaging is the last step in production but first impression for the customer.

Packaging materials decides the quality, shelf life of finished products.

Following packaging materials are used in Parle.

1. Wrappers

2. Polybags

3. Carton Boxes

4. Plastic Jars

5. PVC Trays

1) Wrappers1.1. Parle has its own wrapper production at Neemrana (Rajasthan) plant

1.2. Wrappers used are same (visually) for 82.5 gm, 38.5 gm, 209 gm & 313.5 gm Parle-G products but dimensions are different.

1.3. Wrapper dimension is fixed as per the Parle standard.

Printing Details

1) Every wrapper of Parle-G or Golden Arc or Milano contains necessary information as per PFA rules.

2) It contains

Net wt, Bar code system, packaging date, MRP or price, nutritional facts.

Brand Name, product name, variety, Best before use.

BOPP

These wrappers has tolerance limit of temperature of 1700 C

2) Polybags 1) Polybags contains packets & these bags are then packed in C-Boxes.

2) Before using polybags are analyzed in Quality Assurance Process Laboratory.

3) Polybags are of High Density Polyethylene.

3). C-Boxes -1) Corrugated Boxes consist of more than one sheet of Flute paper.

2) It is made up of flute paper, corrugated paper (Kraft paper).

3) It is of 2 Ply, 3 Ply, 5 Ply .. 18 Ply.

But in Parle c-boxes are upto 5 Ply.

4) For Parle-G c-boxes used are of 3 Ply & for Golden Arc, Milano both 3 Ply & 5 Ply.

4). Plastic Jars- 1) Parle-Khopoli Plant has its own production.

2) These are used for delicates or perishable biscuits e.g Golden Arc

3) Jars are used only for Golden Arcs as its shelf life is less due to high moisture & fat content.

4) Biscuits packets are packed in jars and jars are packed in C-Boxes.

5). PVC trays / Plastic Trays1) These trays are used for Golden Arcs & Milano

2) These are used to prevent the slanting & also used to prevent the damage.

3) Trays are covered in or packed with wrappers.

These are the packaging materials used in the company.

During packaging of polybags it contains one coupon there is information of the plant, product, date, Machine number where it is packed, Batch No., Packing date.

If there is any problem in polybag during transport or marketing then this coupon helps the dealer to inform the company.

Also while dispatching these C-Boxes have some information as

Toatal no. of packets & wt. of one packet.

Name of the mother plants, address.

Shift, Plant no, instruction & tolerance limits.

Corrugated Box Unit 1) Parle Khopoli company has its own c-boxes manufacturing unit.

2) These c-boxes are also supplied to contract manufacturing units.

3) C-Boxes are daily produced as per the demand.

Machineries in C-Box unit

Corrugation Machine

Pasting Machine

Hot Plate

Rotary Cutter

Cut up Machine

Printing & slotting machine

Stitching Machine

Strapping Machine

Each machine has different function than other machine. Process starts from Corrugation Machine up to Strapping Machine.

Process in Detail

1) For C-Box preparation a special type of paper is required i.e. Corrugation paper.

2) Also flute paper is used which sticks on corrugation paper by gum.

3) Corrugation & fluting paper are sticked by using gum & forms liner by suction.

4) Corrugated paper is sucked by pressure & form a ply.

5) Later on pasted paper & previous liner paper are sticked & transferred to hot plate.

6) On hot plate with the temperature of 2200C paper is formed.

7) Prepared paper is cut on rotary cutter in two sheets.

8) On rotary cutter height & width of paper is maintained.

9) On cut up machine length is maintained so, here paper is cut as per length.

10) Later on printing is done which contains coding, brand name, mother plants & location etc.

Parle

Code

No. of pkts X wt. of one packet Max

Stacking

Biscuit

BoxesMktd. by

Packed

Batch no.

KP11) These boxes are supplied to Packaging section.

Suppliers of corrugated paper-1) Vaibhav Paper mill - Vapi

2) Gajanan Paper mill - Buldhana

3) Rajeshwari Paper mill - Nashik

C-Boxes are supplied to following CMUs

1. Bunty Foods - Ambarnath

2. Shivangi Bakers - Khamgaon