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Cadbury is a confectionery company owned by Kraft
Foods. Headquartered in Uxbridge, London, United
Kingdom, the company operates in more than 50
countries worldwide.
The company was known as Cadbury Schweppes plcfrom 19692008.
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Major chocolate brands produced by
Cadbury include the bars Dairy Milk,
Crunchie, the boxed chocolate brand MilkTray; and the twist-wrapped chocolates
Heroes.
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Bournville, the home of Cadbury, is the largest
of several processing and production sites
across the UK.
Each week Bournville alone produces more
than 1,800 tonnes of chocolate or 1.6 millionbars of different sizes.
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Manufacturing at Cadbury
Cadbury uses three main manufacturing methods.
Job production - To make one-off products
Batch production - To make fixed quantities of
products in batches
Flow production - To make large numbers of
identical products
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There are two stages in manufacturingfood products:
Primary processing Converting raw
materials into ingredients.
Secondary processing Processing
ingredients to make food products.
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After Production
Once Cadbury chocolate has been produced, it is
used to manufacture a wide variety of products.
The chocolate and any additional ingredients are
pumped from holding tanks to different production
lines.
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Countlines - These products are made by
the enrobing method.
Moulded bars - Moulded bars are made
by pouring liquid chocolate into bar-
shaped moulds.
Selflines - Selflines are identical chocolate.
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Technology
Cadbury uses computerised scales, boiling vats, date-
stamping machines etc.
Depositors
Mandolines
Bench or floor-standing mixers
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The use of computers to perform fast,
accurate, repeatable production
processes reduces the possibility of
human error and helps make sure thatthe product is always exactly the same.
Cadbury uses specialised machineryfrom both Britain and abroad.
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Quality Control at Cadbury
Cadbury uses a system called Hazard Analysis Critical
Control Points (HACCP).
Quality control checks might include visual, weight,
temperature, microbiological, pH, chemical and
metal checks, as well as organoleptic checks.
Cadburys plants operate 24 hours a day, producing
products to the highest standards of quality control.
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The Cadbury Dairy Milk Bubbly plant, for
example, produced bars with such
precision that the tiny air bubbles in thechocolate were within 0.20.3 mm of each
other.
Factors such as temperature are monitored
at about 1,000 points in the plant, feeding
information to central computers, which
can deal with 360,000 instructions aminute.
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Maintaining the Quality
Cadbury adopts new Pathogen testing system
Cadbury has stepped up its mircobiological surveillance
by adopting the Patharix pathogen testing system.
This system allows cadbury to test large samples of afood product at one time.
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The system is fast and efficient.
Strict quality control tests take place
when the cocoa beans are bought
from the farmers and duringtransportation to ensure high
standards.
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TQM in Cadbury
Cadbury monitors the production process by
using total quality management to ensure that
the chocolate/products that are produced are
of a high quality.
To enforce total quality management Cadburys
have supervisors that monitor the machines,
the other workers and the products that are
made.
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Legal Issues
UK food labelling laws are very specific about what
can and cannot be called chocolate.
The Food Standards Agency is responsible for
checking that the law is upheld on the safety of
materials that come into contact with food.
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Labels must contain certain information,
e.g. the products name, the companys
name, a list of ingredients, special storageinstructions). Companies have to make sure
they know what the law is and that they
conform to it.
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Milk chocolate must either be:
20:20, with a minimum of 20% dry cocoa solids (ofwhich 2.5% non-fat cocoa solids) and a minimum of
20% milk solids (minimum 5% milk fat).
Dairy Milk is this type of milk chocolate
14:25, with a minimum of 25% dry cocoa solids (of
which 2.5% non-fat cocoa solids) and a minimum of
14% milk solids (minimum 3.5% milk fat). This type
of milk chocolate can be called "European or
coating chocolate".
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