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M.ARSHAD

Internship report

5/23/2015

INNOVATIVE BISCUTS Pvt. Ltd

Submitted by: Muhammad Arshad

Roll No. 2063

Submitted to: Dr. Tahir Nadeem

Session: 2011-2015

(BS Food Science and Technology)

It is certified that no objectionable material is added in this report MR sign:

………………………………..

M.ARSHAD INTERNSHIP REPORT 1

ACKNOWLEDGMENTS In performing my internship, it's a successful one I had to take the help and guideline of some

respected persons. First of all I am grateful to Allah who gives me sound mind & sound health

to complete my internship at INNOVATIVE BISCUITS PVT. LTD. The completion of the

task gives me much Pleasure. Then I would like to thank Mr. Muhammad Shahzad (Factory

manager) for providing opportunity, good environment and facilities to complete this

internship. Besides, I would like to thank Mr. Khawar (Senior QA manger), Mr. Zameer

Haidr (QA manager), Mr. Nauman (Production manager) and Miss Shazia (Assistant

production manager) for sharing their knowledge and guiding in right directions.

In addition, I would like to thank to my classmate because of the availability from all of them

while discussing the topic, experience and ideas of this internship

Besides that, I would to appreciate my internship supervisor Miss Mariaum Riaz. She is the

person that in-charge in order to evaluate my assessment and performance related in working

industry. 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. Aamir Sheikh (Managing

Director) 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….


INNIVATIVE BISCUITS (PVT) LTD.

INTRODUCTION AND HISTORY OF COMPANY The company was formed in 2004 and today 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. Our highly committed and professional management team injects vigor and

excellence in every function of the business through strong experience in Marketing, Sales,

Production, R&D, HR, and Quality Assurance.

Innovative has consistently carried forward the banner of happiness for 11 years, so that the

brand name has now become synonymous with quality in biscuit and confectionary

manufacturing. With an emphasis on excellence in every area, we select the finest ingredients,

ensure hygienic conditions at every manufacturing stage and strive to deliver our promises to

the consumer. Quality and purity is set not only on our production floor but in our every

promise, principle and way of doing business. We have a strict policy of ensuring that no

artificial flavors and no artificial colors are added in any of our products. For all these

reasons, we enjoy the full trust and confidence of our consumers.

Innovative has consistently carried forward the banner of happiness for eleven years, so that

the brand name has now become synonymous with quality in biscuit and confectionery

manufacturing. With an emphasis on excellence in every area, we select the finest ingredients,

ensure hygienic conditions at every manufacturing stage and strive to deliver our promises to

the consumer. Quality and purity is set not only on our production floor but in our every

promise, principle and way of doing business. We have a strict policy of ensuring that no

artificial flavors and no artificial colors are added in any of our products. For all these

reasons, we enjoy the full trust and confidence of our consumers.

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 Unit is manufactured by Vicar Spooner (UK) the world’s best biscuit

machinery manufacturer. The company at present has the capacity to produce approximately

1.5 Tons biscuits per hour.

At Innovative, we also proudly uphold our corporate social responsibilities with a firm

commitment to protection of the environment and through productive contributions to

society.

Our passion for innovation has resulted in the finest brands now under its umbrella. Our range

of brands includes Biscuits, Wafers and Chocolates.

PRODUCTS

A variety of products is being produced at innovative under different brand names. Innovative

has three brand names for biscuit, wafer and chocolate.

1. Innovative

2. Cutees

3. Taste Maker

BISCUITS BRANDS WITH THEIR PRODUCTS

Innovative:

Jumboo

Goodies

Goodies with lemon flavor

Digestive


Peanut

Zeera

Choc N Chip

Xtra

Cutees:

Topper

Too Good

Pea Nut

Super Crunch

Fighter

Tracker

Taste makers:

Peanuts

Tea Time

Elaichi special

Pista Maza

Kingo

Snoper

WAFERS BRAND WITH THEIR PRODUCTS

Cutees:

• Plus Orange Wafers

• Plus Custard Wafers


• Plus Strawberry Wafers

• Plus Chocolate & Vanilla Wafers

Tastemakers:

• Orange wafers

• Mango wafers

• Chocolate wafers

• Strawberry wafers

Innovative:

• Trend Orange

• Trend Orange

• Trend Chocolate

• Wafers Creamy orange flavor

• Wafers Creamy Chocolate Flavor

• Wafers Creamy Strawberry

Flavor

• Wafers Creamy Vanilla

Flavor

Frisky:

• Orange cream wafers

• Vanilla cream wafers

• Chocolate cream wafers

• Strawberry cream wafers


CHOCOLATE COATED WAFERS

BRAND WITH THEIR PRODUCTS

Innovative

• Chocos

Taste makers:

• Spark

• Chocolate wafers

• Orange wafers

• Mango wafers

• Strawberry wafers

Cutees:

• Pick

• Tropik


EQUIPMENTS AND MACHINARY

USED IN INDUSTRY:

WEIGHING BALANCE:

A weighing balance is an instrument capable of making

precise measurements of weight of objects. Weighing balance

is used to weigh different ingredients. There are two types of

weighing balance at plant. Least count of lab scale weighing

balance is 0.01g and mainly used to weigh the small fraction such

as salt, soda, biscuit weight etc. Second category balances are used

to weigh large quantities of materials in kilograms and have least

count of 0.01kg. All the weighing scales are electronic and have digital displays.

WAFER MIXER:

Wafer mixer is used to mix the flour to make the batter for wafers. The water absorption

of flour may be important in mixing and this is strongly affected by the moisture and

protein contents. There are four lines of wafer and one line of chocolate coated wafers and

every line has its own mixer. There are two tanks of one mixer. One tank has an

arrangement of mixing mechanism upward the tank and second tank is used to hold the


batter for loading for further processing and uploading of batter is automatic according to

need of oven.

WAFER OVEN:

Wafer oven is used for baking wafer sheets. Wafers are a very specialized type of biscuit

requiring special equipment for production. The sheets formed by baking between pairs of

heated metal plates, which are like large

steel book leaves hinged at one side, are

typically thin and usually bear intricate

surface patterns with deep relief derived

from the baking plates. Wafer sheets are

baked from a simple batter containing

little or no sugar. They are rather tasteless

and have a regular surface and a very

open cellular structure within. All the

oven have 65 plates and can operate on three speeds, 18, 20 and 22 respectively. Baking time

and temperature depends on speed of oven.

COOLING TOWER:

Cooling tower is used to cool the wafer sheet. It

can hold 51 sheets at a time and directly drops

the sheets on creaming machine conveying belt

for the creaming of sheet. Cooling time also can

be adjusted according to requirement.


CREAM SPREADING MACHINE:

Cream spreading machine is

used to spread. Wafer cream

spreading machines spread

an exact amount of fat cream

onto the wafer sheets and

automatically stack the

requested number of spread

sheets together with the

uncreamed top sheet into a

wafer block. The speed of

the two rollers and of the spreading belt can be adjusted independently of each other. The

uncreamed top sheet passes the spreading roller without contact due to cam-controlled

lowering of the spreading table. After spreading wafer blocks are formed out of three or four

wafer sheets with the spiral stacker. There the wafer sheets get maximum support and are

stacked. Exact block formation

guarantees a minimum of cutting

residue in the following cutting

process.

WAFER CUTTING

MACHINE: It is a steel wire cut machine to

cut the wafer sheets, which size is

adjustable through horizontal and vertical to finish cutting automatically. Sometime three

layer sheet in processed and sometime two sheets of three ply sheet are combined to process.

No of fingers produced from one sheet (three ply or six ply) depend on the space between

steel wire cut horizontally and vertically. A wafer cutting machine having eleven wires

horizontally and nineteen vertically can cut a sheet into 180 pieces because both sides are

wasted during wire cut


MIXER FOR CREAM MIXING:

Cream mixer is used to mix the cream, sugar, flavor and color for proper application of cream

to the wafer sheets.

SUGAR GRINDER:

Sugar grinder is used to grind the sugar in to desirable crystal size to sprinkle on the product

or to add in cream etc.


MOULD:

Mould is used to give the shape to

biscuits. Mould is different for

different products.

BISCUITS BAKING OVEN:

Biscuits baking oven is used to bake the biscuits. Length and width of all biscuit baking oven

are different and number of burners also vary. Mainly two type of ovens are being used to

biscuit baking.

1. Direct Oven: There are number of burners on the bottom and top of the steel belt

congaing 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.

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.

1. First zone raises the biscuit.

Here the biscuit is allowed to

rise as much as possible.

2. Second zone bakes the biscuit.

3. Third zone gives color to the

biscuits.

Escape of gases and steam would result

in collapse of structure hence these are


passed on to different zones with gradual increase or decrease of temperature zones.

Some types of ovens also have five zones which give certain characters to the product.

Following are the physical and chemical changes which occur in oven, when dough

piece is passed on to oven.

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

Chemical changes:

1. Gas formation

2. Starch gelatinization

3. Protein changes

4. Caramelization of sugars

BISCUITS STACKER:

Biscuits stacker is used to stack the biscuits. There are number of rows according to product

that are stacked into rows/lines for packaging.


BISCUITS

Ingredients: Toper:

• Water

• Wheat flour

• Hydrogenated vegetable oil

• Corn flour

• Fresh eggs

• Sugar

• Glucose syrup

• Skimmed milk powder

• Leavening agents {sodium bi carbonate, ammonium bicarbonate}

• Salt

• Artificial flavor

• Permitted food colors


Jumboo:

• Water

• Wheat flour

• Sugar


• Glucose

• Salt

• Raising agents (Sodium Bicarbonate E500 and Ammonium Bicarbonate E503)

• Soya Lecithin E322

• Calcium Carbonate E170

• Sodium Pyrophosphate E450

• Artificial Flavors

Choc ‘n’ chip:

• Water

• Wheat flour

• Vegetable oil

• Chocolate chips

• Raising agents (Sodium bicarbonate, Ammonium bicarbonate)

• Salt


• Permitted food color

Snoper:

• Water

• Wheat flour


• Vegetable oil

• Sugar

• Corn Flour

• Skimmed Milk Powder

• Fresh Eggs

• Salt

• Leavening Agents

• Acritical Flavor

• Permitted Food Color

Peanut:

• Water

• Wheat flour

• Hydrogenated Vegetable Oil

• Sugar

• Peanut Grits

• Skimmed Milk Powder

• Fresh Eggs

• Salt

• Leavening Agents (Ammonium Bicarbonate and Sodium Bicarbonate)

• Soya Lecithin

• Artificial Flavor


FUNCTIONS OF INGRIDIENTS

Biscuits provide almost double calories for regulation of body activities as compared to bread.

Biscuits are nutritious, convenient food with long shelf life, used as popular item of food.

Biscuits are good source to provide Ca, Carbohydrates, Fe, and Protein etc. Biscuit vary in

size, shape, texture, hardness, so biscuit making require great care, attention & keeping

quality level for producing a standard & better product

FLOUR:

Flour is a very important ingredient which can impart unique appearance,

characteristic to the biscuit. Wheat flour is produced by milling the whole

wheat grain, which contain germ, bran & endosperm, but in biscuit

manufacturing only endosperm is used & is separated from germ & bran,

which is called as:white flour, Maida”

Gluten Formation:

When wheat flour is mixed with water and st irred or kneaded, the glutenin

and gliadin proteins not only bond with the water but also link and crosslink

with one another to eventually form sheets of a flexible, resil ient film called

gluten. Protein content determines how much water a flour can absorb the

greater the amount.

Functions:

• Flour provides the structure in baked goods

• Acts as a binding agent

• Acts as an absorption agent

• Affects the taste

• Provides nutrition in final product

• Retain shape and volume after baking

• Major constituent of biscuit.


• It contains four proteins: Albumin, Globulin, Glutenin (controls

strength & structure of biscuit) & Gliadin (gives elasticity to the

dough). Albumin & Globulin are soluble proteins. Glutenin & Gliadin

are insoluble proteins. Insoluble proteins combine with water to form

“Gluten”, & Gluten along with starch provides proper eating qualit ies.

FAT:

• Fat provides nutrition, flavor & aids in development of physical

structure.

• Fat provides shortness and tenderness.

• Helps in flavor development

• Help in Emulsification

• Help in Aeration (creaming)

• Helps in heat transfer

• Improves the eating quality for prolong period

• Improves keeping quality of the product & increases i ts shelf life

WATER:

Water is a basic ingredient in baking. It would be impossible to produce biscuits without

water in some form. It facilitates mixing of ingredients and other steps of processing. There

are certain functions of water which include:

• It makes possible the formation of gluten.

• It wets and swells the starch.

• It assists in controlling the temperature of dough a through adding cold or warm water

the temperature of the dough can be regulated.

• It dissolves salts, suspends and distributes non-flour ingredients uniformly.


RAISING AGENTS:

• Sodium bicarbonate: (NaHCO3)

It is also known as baking soda. It releases carbon dioxide on being exposed to moisture and

acid. In baking, it is used for leavening or giving volume to breads, cookies, cakes, and some

candies. The volume and texture of the product depend largely on the amount added to the

batter or dough. Besides damaging the volume and texture, excess use of baking soda leaves

an after- taste and gives a light color to the finished product. Baking soda is often used in

chocolate cakes and cookies to raise the pH of cocoa.

• Ammonium bicarbonate:

It is used to a small extent as a leavening agent. Its use is primarily limited to a certain types

of cookies. The advantage of this type of leavening agent is that it decomposes into two gases

and does not leave a solid residue.

SALT:

It is used for flavor and taste. It brings about the taste of other ingredients. Table salt should

have the following characteristics for use in the bakery items:

• It should be completely soluble in water.

• It should give a clear solution. Cloudy solution indicates presence of certain

impurities.

• It should be free from lumps.

• It should be as pure as possible.

• It should be free from a bitter or biting taste.

Functions:

• It is mainly added for taste

• Most effective concentration is around 1 – 1.5 % based on flour weight

• Used for flavor & flavor enhancing properties

• It should be completely soluble in water.


• It should be pure, free from lumps.

• Prevents the growth of undesirable bacteria in yeast raised dough

SKIMMED MILK POWDER:

Milk contributes valuable nutrients to baked goods. It helps browning to occur, adds flavor

and improve texture. This is done to improve the quality of the dough and the volume of the

biscuits.

Dry milk used in the bakery products should be readily soluble.

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”. The flavor of this

milk is very strong & is used in many ways during manufacturing of biscuits.

• SMP is a major dough ingredient, which is used to give flavor, texture & aids in

surface coloring.

• It has a binding effect on flour protein, creating a toughing effect.

• Improves flavor & is an important moisture retaining agent.

EMULSIFIERS:

It is added to the dough during mixing to mix two immiscible things. Some of the more

common ones are monoglycrides, calcium steroyl lactylate, and sodium steroyl lactylate.

Some anti-staling ingredients also perform as dough conditioners or dough strengtheners.

Soya lecithin is being used as emulsifier in biscuits.

To stabilize mixtures of two immiscible liquids (normally oil & water), e.g., Soya Lecithin.

Soya lecithin is obtained from Soya origin. Being natural, it is exempted from controlled by

legislation. In any mixture of water & oil, lecithin exhibits a pronounced emulsifying action

by reducing the surface tension at the interfacial boundaries existing b/w oil & water phases.

This results in two distinct effects.

• Stabilizing oil in water emulsion

• Stabilizing water in oil emulsion


SUGAR:

Basic function of sugar is that, it provides sweetness. Besides this, it enhances flavor and

aroma. It helps in browning by caramelization reaction and imparts color to

the bakery items. It also increases the product’s shelf life by increasing its

moisture retention. Sugar is not considered an essential ingredient in baking. This is

because flour contains a small amount of natural sugars

• Imparts sweetness

• Contribute to eating texture

• Increase crispiness of biscuit

• Browning effect

• Fuel for yeast

• Extents shelf life

DEXTROSE:

• It is a simple sugar, can occur naturally in some food & honey but industrially

produced dextrose usually made from corn starch.

• Also helps in baking.

• Major role in taste, texture & color development.

BUTTER:

Butter is made from cream and has a fat content of at least 80 percent. The remaining 20

percent is water with some milk solids. Butter imparts a good flavor without a greasy mouth

feel to baked goods because it melts at body temperature. It adds valuable nutrients to the

biscuits.

EGGS:

Serve many functions in baked goods. They add flavor and color, contribute to structure,

incorporate air when beaten, provide liquid, fat, and protein, and emulsify fat with liquid


ingredients. Reducing or omitting egg yolks can result in less tenderness. If a low fat, low

cholesterol baked product is desired, use 2 egg whites for 1 whole egg; the white has very

little fat or cholesterol. When a recipe calls for an egg, the best size to use is a 2 oz. Grade A

large eggs.

• Eggs contribute flavor to the product.

• Act as emulsifier

• Helps in smooth & even texture of the finished product

• Contributes to the structure of baked product

• Contribute color, nutritional value & desirable flavor

• Improves characteristic organoleptic qualities of biscuit

ARTIFICAIL FLAVORS:

These are used toad or enhance flavor of product. Good quality flavors must be used.

• Primarily used to improve the flavor of the product

• Used in dough & cream

• Different flavors used in biscuit making are vanilla flavor, strawberry flavor, chocolate

flavor, peanut flavor, lemon, butter milk flavor, butter flavor, condensed milk flavor,

mango flavor etc.

COCA POWDER:

An unsweetened powder made from the left over chocolate liquor. The chocolate liquor is

made from cocoa beans & about 75% of it is extracted as cocoa butter and the remaining is

bright and ground into cocoa powder. It is used to add chocolate flavor to baked goods.

SMS (SODIUM METABISUPHITE)

• Used in very small quantity to modify the gluten quality chemically.


• It causes the gluten to become more extensible & less elastic, therefore reduces the

shrinkage of dough pieces as they are baked

• It is useful processing aid to compensate for the variations in gluten quality

BISCUIT SECTONS

FLOW DIAGRAM: Raw material Lab analysis Storing Weighing & sifting

Cooling Baking Rolling and shaping Mixing

Stacker Sorting & packing Storing Dispatch

PROCESSING LINE FOR BISCUITS

1. Raw material:

Raw material used for different biscuits is received at factory and is analyzed as described in

lab work section.

2. Lab analysis:

All raw material is analyzed in Lab and those materials which fullfil the standard

requirements are then used.

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.

Weighing & sifting:

• Scale all ingredients accurately.

• Sift the dry ingredients together into a mixer.

4. 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.

5. 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.

All products must pass through correctly functioning metal detector.

Industry sets standards for detection of metal pieces. It is checked daily and after each hour

and quality sheet is filled.

6. 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.

7. Baking:

It is the technique of prolonged cooking of food by dry heat acting by convection, normally in

an oven, but also in hot ashes, or on hot stones.

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. This is a general scheme. The time can be varied due to variation

in weight.


Cooling:

After baking, cooling is done. A cooling under controlled conditions ensures a perfect and

lasting preservation of the packed biscuits. By mounting a special mesh belt-shifter, no

sideslip is possible. The forced cooling is obtained by air-flow line with centrifugal fan. All

necessary safety devices and sanitary materials are used. 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.

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

• The weight of 10 biscuits

according to standard

• There is no color variation.

• The biscuits are sound and

separate from each other.

• The diameter is according to

standard


Packing:

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:

(a) Name or trade-name of the biscuit,

(b) Name of the biscuit manufacturer,

(c) Batch or code number,

(d) Net weight in grams (g) or kilograms (kg), and

(e) The statement ‘Permitted flavoring and coloring agents used”

Storing:

The finally packed product is stored in ware house or dispatch room.

Dispatching:

Then the product is dispatched to market.


Quality defects in biscuits:

• Over baked

• Under baked

• Small diameter

• Broken biscuits

• Fin seal and end seal problems

• Wrapper printing problems

WAFERS SECTION 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. The sheets formed

by baking between pairs of heated metal plates, which are like large steel book leaves at one

side, are typically thin and usually bear intricate surface patterns with deep relief derived from

the baking plates. Wafers which are sold in biscuit markets are usually formed as large flat

sheets which are rigid as they come from the oven and these are subsequently sandwiched

with cream or caramel before cutting with saws or wires. They may be chocolate enrobed or

included in molded chocolate

INGRIDIENTS:

• Water

• Wheat flour

• Grinded sugar

• Corn oil

• Cream

• Salt


• Soya lecithin

• Artificial color


• Sodium bicarbonate

• Skimmed milk powder

• Dextrose powder

• Antioxident


FLOW DIAGRAM: Raw material Lab analysis Storing Weighing & sifting

Cooling Baking Sheeting Mixing

Creaming Cutting & enrobing Packaging Dispatch

`

PROCESSING LINE FOR WAFERS: 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.

Lab analysis:

All raw material is analyzed in Lab and those materials which fullfil the standard

requirements are then used.


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.

Weighing & sifting:

• Scale all ingredients accurately.

• Sift the dry ingredients

Mixing:.

• Add chilled water in the mixer.

• Add the dry ingredients to water in the mixer.

• Mix them until the ingredients are uniformly mixed. Do not over mix. It takes

about 8-10 minute to mix properly.This gives us batter.

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.

Cooling:

After baking these sheets are cooled on the moving belt. It takes about two and half minutes

for cooling. Then these sheets are transferred to the creaming section. Here the broken sheets

are separated from sound ones. The weight of 3 plane sheets after cooling should be 120 to

125 gram.

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.


o Creaming method:

The cream is prepared in a separate cream mixing machine from where it is transferred to the

hopper of creaming machine.

For cream preparation cream, sugar, color and flavor are added and mixed for three minutes in

a cream mixer. The following ingredient is also used during mixing:

• Cocoa powder for chocolate cream

• Vanilla powder for vanilla cream


Cutting:

The sheets are cut with a cutting machine and the sound wafers are shifted to the packing

section.

Enrobing:

Chocolate coated wafers are enrobed in chocolate.

Packing:

The wafers are manually placed in plastic tray and are packed mechanically in wrappers. Then

the small packkets are packed in large packaging and then are covered with cellophane paper.

The Mfg and Expiry dates are mentioned on the packing.

The following particulars shall be clearly and indelibly marked on label on

each container:

(a) Name or trade-name of the biscuit,

(b) Name of the biscuit manufacturer,

(c) Batch or code number,

(d) Net weight in grams (g) or kilograms (kg), and

(e) The statement ‘Permitted flavoring and coloring agents used.


Storing:

The finally packed product is stored in ware house or dispatch room.

Dispatch:

Then the product is dispatched to market.

Requirements:

• Wafers will be properly baked and will not show signs of under baking or over

baking.

• They will be crisp, crunchy and light in texture. The design impressed on them, if

any will be clear.

• They will have an agreeable odor typical of well-baked wafers, and will be free

from soapy or other objectionable flavors.

• They will not have insect and fungus infestation.


CHOCOLATE: This section was not functional due to summer

session

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.

Sr #

Raw material Quantity No of samples

Analysis Standard for Acceptance

1 Ammonium bicarbonate (Ammonia)

50 bags 2 bags Solubility 100% Purity

2 Brown sugar Moisture % 0.5 % Ash % 0.1% Color Brown Granulation

Uniform fine crystals of sugar

Solubility 100 % 3 Bran

(choker) 20 bags 2 bags Moisture%

Ash % Substandard %

4 Chocolate chips 15 tn Random sampling from the lot

Substandard 5 specks in 100 gram max

No. of pcs in 10 gram

80-90 pcs

5 Cocoa powder 100 bags 200 bags

Random sampling from the whole lot

Moisture - Smell Chocolate smell Appearance Dark brown finer

powder without caking 6 Colors - - solubility 100% 7 Dessicated

coconut 20 bags 2 bags Moisture 3-4 % max

FFA 0.3% max Rancidity Nil Fat % 60- 65 % (range)


Color Natural white Smell

Free from rancid, musty or objectionable odor

Taste

Mild and sweet coconut taste with no off flavor

Impurities

No more than 5 dark specks in 100 grams

Granulation Uniform granules 8 Dextrose 100 bags 4 bags Moisture 10 % max

Solubility 100% Color White Taste Light sweet Appearance

Crystalline fine granules/ powder

9 Desi ghee (Tarkka)

10 tin 20 tin

1 tin 2 tin

FFA 0.1 % max POV Nil Rancidity Nil SMP 39- 41 °C SFI - MFG/EXP date

10 Eggs 25 pati 50 pati

Inspection of the whole lot

Physical appearance

No blood spot or dirt/dust etc

Substandard% 0.05% Weight of 10 eggs

Min 500 g

11 50 kg 100 kg

Random sample

Specific gravity

12 Full cream milk powder (FCPM)

10 bags 25 bags 40 bags 50 bags

1 bag 2 bags 3 bags 4 bags

Moisture 7 % max Solubility 100% Color White Taste Sweet with no off smell Appearance Fine powder with no

caking 13 Flavo

r Liquid 100 L Random

sampling from cans

Specific gravity - Smell Specific smell

according to standard Powder Smell According to the

standard 14 Golden syrup 10 cans Random

sampling from cans

moisture Viscosity

18-22%


15 Hellu syrup 10 can Random sampling from cans

moisture Viscosity

18-22%

16 Lecithin 10 drum 1 sample Emulsion formation

Uniform emulsion formation

17 Liquid Glucose 100 cans 150 kgs

Random sampling from cans

moisture Viscosity

18-22%

18 Oil 10 tin 20 tin

1 tin 2 tin

FFA 0.1% max POV Negative (qualitative) Rancidity Negative (qualitative) SFI - MFG/EXP date

19 Oat flour (Jambo Atta)

10 bags 20 bags 30 bags

1 bag 2 bags 3 bags

Sieving

Zero tolerance for beetles and foreign maters

Moisture 14.5 % max Ash 0.5 % max

20 Peanut 25 kg 50 kg

2 bags 3 bags

Moisture% 5 % max Fat % 40-50 % Smell Normal Impurities

No more than 5 dark specks in 100 grams

Taste Fresh peanut taste 21 22 Salt 20 bags



Solubility test 100% Impurities test Nil Color White Appearance Fine powder Purity 98% Moisture % 0.5 % max

23 (SAPP) Sodium acid pyrophosphate

5 bags 1 bags Solubility 100%

24 Skimmed milk powder (SMP)



Moisture 7% max Solubility 100% Color Off white to white Taste Normal without off

smell Appearance Fine powder without

caking 25 Sodium

bicarbonate 50 bags 2 bags Solubility 100 %


26 Soya flour 10 bags

20 bags 30 bags

1 bag 2 bags 3 bags

Sieving


Moisture % 5 % max Gluten % 0 % Ash % 5 % max Fat % 20 % max

27 Starch 20 bags 50 bags 100 bags 200 bags


Moisture % 13 % max Ash % 0.2 % pH value 4.5-7 Smell No disagreeable smell Color Pure white Appearance Homogenous free

flowing powder 28 Sugar 50 bags

100 bags 200 bags 400 bags 600 bag

1 bag 2 bags 4 bags 8 bags 10 bags

Moisture % Solubility

0.5 % max 100%

Impurities

Not more than five specks in 100 gram sample

Ash % 0.05 % max Color Sparkling white Granulation Uniform fine crystals

of sugar 29 Vegetable Fat 400 carton

800 carton 1200 carton

4 ctn 8 ctn 12 ctn

FFA 0.1 % max POV Negative (qualitative) Rancidity Negative (qualitative) SMP 38- 41 °C SFI - MFG/EXP date

30 Wheat flour (Maida)


2 bags 3 bags 4 bgas 5 bags

Sieving


Gluten % 8.2 – 9.8 % Moisture % 14.5 % max Ash % 0.5 % max MFG/EXP date Must be labeled

31 Whole wheat flour (Atta)


1 bag 2 bags 3 bags

Sieving


Gluten % 8.2 – 9.8 % Moisture % 14.5 % max Ash % 0.5 % max


32 Whey powder 10 bags 25 bags 40 bags 50 bags


Moisture 7 % max Solubility 100% Color

particular size Uniform Yellowish

Taste Normal Appearance Dry and uniform

texture without caking 33 Zeera

Cumin seeds 30 bags 2 bags Impurities

Seeds with max 10 specks in 100 gram

Smell No off smell. Appearance Dry and clean seeds

34 Zeera powder Cumin powder

5 bags 10 bags

1 bag 2 bag

Moisture Smell No off smell Color Dark brown powder

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

3. Ash

GLUTEN TEST:

Wheat flour possess unique properties of forming Visco-elastic and resistant to extension

dough. Gluten is protein. Gluten is formed by two components.

Gliadin: Elasticity in dough is due to gliadin.

Glutenin: Resistant to extension dough is due to glutenin.

The above two fractions are when hydrated, gluten is formed.

On the basis of Gluten percentage, flour is divided into three categories.


1- 9-10 % Soft Flour

2- 10-11 % Semi-hard Flour

3- 11 % or more Hard Flour

In Biscuit manufacturing mostly soft Flour with less gluten percentage is required for most of

the varieties (soft dough biscuits and cookies) because in biscuit manufacturing our objective

during mixing is not to develop gluten. That`s why mixing time is short and speed of mixing

is high. On the other hand, in bread industry, flour is mixed for long time and at low speed in

order to develop the gluten. But in biscuit industry, flour is added at the end and then a short

time mixing is given.

Gluten Test Procedure:

a) Apparatus

1. Petri dish

2. Mixing bowl

3. Glass container

4. Hard paper

5. Knife

6. Electric weighing balance

7. oven

b) Procedure

Take 20 grams of flour sample in a Petri-dish by using electrical balance. Put this sample in a

container for mixing. Add 10 ml water in it and start mixing it, preferably with one figure.

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. Washing is carried out in order to remove starch from it. Iodine

test can also be performed in order to check if starch is removed from sample dough. After the

removal of starch, take a small piece if hard paper and dry it. 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.


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.

c) Calculations

Weight of sample w1

Weight of hard paper w2

Weight of wet gluten w3

Wet gluten % age w3/w1 x 100

Weight of gluten and hard paper w4 = w2 + w3

Weight of gluten and hard paper after drying w5

Weight of dry gluten w6 = w4- w2

Dry gluten % age w6/w1 x 100

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)

a) Apparatus

1. Moisture analyzer

b) Procedure


In modern method of moisture analysis, 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 =11.20%

Moisture Test (with Oven)

a) Apparatus

1. China dish

2. digital weighing balance

3. Oven

4. Holder to put out the hot china dish from the oven

5. Desiccator

b) Procedure

Take a china dish and place it in the oven for a few minutes. Then take it out of the oven and

place in the Desiccator till it cools down. Weigh the china dish. Set the oven temperature of

110 0C for two hours. Collect the 5 grams sample in china dish. Put the sample in oven. After

two hours draw the sample from oven. Put the sample in to Desiccator for a few minutes with

the help of a iron holder, than weigh the sample. Repeat this process three or four time, until

received the constant weight.

c) Calculations

Weight of sample w1

Empty plate weight w2

Weight of china dish and sample before drying w3= w1+ w2

Weight of china dish and sample after drying w4

Net sample weight w = w3 – w4

Loss of moisture w1-w

Moisture % loss of moisture x 100 /Sample weight


ASH TEST:

a) Apparatus

1. Crucible

2. digital weighing balance

3. Oven

4. Hot plate

5. Fume hood

6. Holder to put out the hot crucible from the furnace

7. Muffle furnace

8. Desiccator

b) Procedure

Take a crucible and place it in oven for a few minutes. Take crucible out of the oven and

place it in the Desiccator till it cools down. Weigh the crucible on digital weighing balance.

Take 10 gram flour sample in that crucible and place it on the hot plate in the fume hood,

charring is done until no fumes come out of the flour sample. Charred sample is than placed

in the muffle furnace at 550 °C for 4-5 hours until the flour sample turns into white ash. Take

out the sample from the muffle furnace and place it in the Desiccator till it cools down. Take

weight of the ash.

c) Calculations

Weight of sample w1

Empty crucible weight w2

Weight of crucible and sample before ashing w3= w1+ w2

Weight of crucible and sample after ashing w4

Net weight of ash w = w3 – w4

Ash % Weight of ash X 100 / Sample weight

= (w/w1) x 100


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)

FREE FATTY ACID (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.

a) Apparatus

1. 3 glass cylinders(50 mL)

2. 250 mL flask

3. 3 pipettes

4. Sucker

5. 50 mL burette

6. Digital weighing balance

b) Chemicals

1. Ethanol

2. Fat sample

3. Di-ethyl ether

4. 1% Phenolphthalein solution

5. 0.1N KOH solution


c) Procedure

Take 25 ml of Ethanol and 25 ml of Di-ethyl ether in flask. Add 2-3 drops of phenolphthalein

indicator solution and shake it. Then titrate it against 0.1N KOH till light pink color appears.

This is done in order to neutralize the solution. Then take10 grams sample of fat in the same

flask, and mix it.

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.

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 the tip

while the solution is flowing. Dry the tip of the burette and check to see if the burette is

leaking.

In this experiment the burette contains KOH.Titrate the fat solution until the colorless end

point appears.

d) 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

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

Chemicals

1. Fat sample

2. 37% conc. HCl

3. 0.1% Phloroglucinol (solution made in ethanol/ether solvent)

Procedure

Take a small amount of fat sample in the flask with the help of specula. Take it in oven for

some time so that it melts completely. 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 %). Again shake and

observe the color. Change in color will be rejected. If color match with original sample then it

is ok.

Rancidity in the given sample = Nil

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.

a) Apparatus

1. Test tube

2. Test tube holder

3. Test tube stand

4. Burner

5. Two capillary tubes

6. Thread


Procedure

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. 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. Take ½ - 1 inch of the sample in them and

put these capillary tubes in freezer for about five minutes.

Then take water bath and arrange the temperature of water bath to 10 °C or less than this. 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.

SMP of the given sample.

ANALYSIS OF FINISHED GOODS Physical characteristics:

• Color

• Weight

• Diameter

• Thickness

Moisture

Total Ash

Fat

FFA

Cream%


Sr #

Finished products

No of samples Analysis Standard for Acceptance

1 Biscuits Random sampling after every two hours

Moisture 2.0 % max Ash 0.05% Fat According to the

product FFA test

0.1% max

Over all packing

According to the standard

Water test No air leakage Packet wt According to the

standard 2 Wafer Random sampling after

every two hours Cream % Over all packing Water test Packet wt

According to the standard According to the standard No air leakage According to the standard

Chocolate Random sampling after every two hours

Over all packing Water test Packet wt

According to the standard No air leakage According to the standard

PHYSICAL TESTS OF BISCUITS 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.

2. Diameter test

To determine the diameter (D), six 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.

3. Thickness test


To determine the thickness (T), six 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.

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 =0.82%

5. Total Ash Test

Total ash is determined by muffle furnace. Ignite the sample at a temperature of 550 °C for 5-

6 hours.

Weight of china dish 53.0861 grams

Weight of biscuits 10.00 grams

Weight of china dish + Ash (After ignition) 53.1572

Ash % 53.0861/53.1572x100

0.07 %

Fat test

The biscuit is first ground to extract its fat. The fat% of biscuits is determined by

1. Soxhlet apparatus.

2. By dissolving in diethyl ether

Soxhlet Apparatus Method

a) Apparatus

1. China dish

2. Digital Weighing balance

3. Desiccator

4. Oven

5. Thimble/ filter paper


6. Soxhlet apparatus

b) Chemicals

Petroleum ether

c) Procedure

Take 5 grams for ground biscuit sample in a china dish. Place it in oven for 24 hours at 105

°C to remove its moisture. Then weigh the sample after drying and wrap it in a pre-weighed

filter paper so tightly that it should not leak form filter paper.

Place the filter paper inside the Soxhlet apparatus. Fill 2/3rd part of the round bottom flask

with petroleum ether. Switch on the heater to start fat extraction from the biscuit sample.

When the extraction is completed, take out the filter paper form the Soxhlet apparatus. Place it

in the oven for a few minutes to evaporate the petroleum ether residues in the sample. Than

weigh it.

d) Calculations

Weight of sample after drying w1

Weight of filter paper w2

Weight of sample and filter paper w1 +w2

Weight of sample and filter paper after fat extraction w3

Weight of sample after fat extraction w4= (w1 +w2) - w3

Weight of fat in biscuit = w1 – w4

Fat% w/w1 x 100

By Dissolving In Diethyl Ether

In second method, biscuits are grinded and then take this sample in a closed container. Add

sufficient amount of diethyl Ether to dissolve fat present in biscuits. Now mix the biscuits in

diethyl Ether and dissolve fat in it. After dissolving fat, remove the diethyl Ether from the


container and pour in a Petri plat. Now dry it on the water bath until all the ether has been

evaporated. Now we have fat, extracted from biscuit

Food Packaging Material Analysis: Food packaging is packaging for food. It requires protection, tampering resistance and special

physical, chemical and biological needs. It also shows the product that is labeled to show any

nutrition information on the food being consumed.

Sr #

Packaging material

No of samples Analysis Standard for Acceptance

1 Film/ wrapper Random sampling from different Reels

Reel Wirth, Length, Thickness, color, moisture

According to set standards

2 Box Random sampling from different places (5-10 % boxes)

Weight, width, length, grammage, lock device, moisture, gumming, color, creasing, flap cutting


3 Carton Random sampling from different places (5-10 % cartons)

Weight, width, length, grammage, lock device, moisture, gumming, color, fluting, creasing, flap cutting


4 Tap Random sampling from different places(5-10 % tapes)

Gum % 50 % minimum

5 Biscuit tray Random sampling (5-10 % trays)

Tray weight Length Wirth Depth

According to the standards

http://en.wikipedia.org/wiki/Packaging_and_labeling

http://en.wikipedia.org/wiki/Food

http://en.wikipedia.org/wiki/Nutrition


List of Packaging material used in Biscuits industry:

1. Films

2. Family pack

3. Dispenser Box

4. Master carton

QUALITY

Definitions:

Conformance to customer’s requirement or degree of excellence is called quality. 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.

Quality control: Part of QMS focused on fulfillment of quality requirements. All corrective

measures are known as quality control. If biscuit color is dark after baking then we take a

corrective step that is quality control.

Quality assurance: Part of QMS which provide confidence that quality requirements are

being fulfilled. All the preventive measures are part of quality assurance. It include personal

hygiene, finished goods inspection safety measures etc.


QUALITY CONTROL AND QUALITY ASSURANCE Quality control and quality assurance are very important for any of ISO & HACCP certified

company. At innovative, quality assurance inspectors control the quality by observing and

analyzing on different points of line from mixing to final packaging. Quality control and

quality assurance departments are same.

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. QA 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.

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. Vernier calipers is also used to

measure biscuit parameters. 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 because first zone is puffing zone, second in

baking zone and third is coloring zone.


Packaging:

After oven, when product enters in packaging area, QA 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.

Quality control reports:

1. Cutting section inspection report

2. Oven baking inspection repot

3. Packaging section inspection report

Quality Assurance reports:

1. Personal hygiene inspection report

2. Finished goods inspection report

3. Plant sanitation inspection report

4. Raw material inspection report etc

GMP’s: Some of the tasks relating to GMP’s in which we took part include:

Plant sanitation inspection

Personal hygiene inspection

Training of workers

IPM


Plant sanitation:

In plant sanitation daily inspection of plant cleanliness was done and quality sheets

were filled. Any non-conformity occurring was checked, noted and informed to the

related persons. The cleanliness of belts, stackers, product trays etc. was checked. A

proper place of everything was checked i.e. empty trays, trays containing the product,

tools, packing material etc.

Personal hygiene & GMPs inspection:

In personal hygiene & GMPs inspection, daily inspection of workers was done and

quality sheets were filled. Any non-conformity occurring was checked, noted and

informed to the related persons.

It was checked that workers are wearing hairnets, clean uniform and shoes, using

gloves, have proper haircuts, trimmed nails etc.

No one is wearing jewelry and suffering from illness, eating or drinking in the

production hall etc.

Training of workers:

Training of the workers is very important. The training of workers is done according

to schedule. The workers are taught about the basic definitions relating to ISO and

then evaluation is done in which they are asked about these definitions.

Further they are taught about personal hygiene and GMPs.

They were also given work instructions in order to efficiently perform their work

leading to quality.

IPM (integrated pest management):

In Integrated pest management. We worked with the spray man and learned about

different activities to control the pests.

These are controlled by different methods as:

• Daily spray is done to control flying and crawling pests.

• Bait stations are used to control crawling insects.

• Glue boxes are used to control rats.


ASSIGNMENT # 1 Contents:

• What is IPM? What are steps for IPM?

• Which insects are found in food industry, their identification and life

spam.

• How many defense lines are present in Innovative and how any insects are

found in 24 hours?

• Conduct a GAP analysis regarding IPM in Innovative

Introduction:

A pest infestation can put your product and your business' reputation at

risk.

The goal of Integrated Pest Management (IPM) is to identify, prevent, and eliminate

conditions that could promote or sustain a pest population with a food manufacturing, storage,

or transportation operation. IPM relies on appropriate assessment, monitoring, and

management of pest activities.

Integrated Pest Management (IPM) is an effective and environmentally sensitive approach to

pest management that relies on a combination of common-sense practices. IPM programs use

current, comprehensive information on the life cycles of pests and their interaction with the

environment. This information, in combination with available pest control methods, is used to

manage pest damage by the most economical means, and with the least possible hazard to

people, property, and the environment. The IPM approach can be applied to both agricultural

and non-agricultural settings, such as the home, garden, and workplace. IPM takes advantage

of all appropriate pest management options including, but not limited to, the judicious use of

pesticides. In contrast, organic food production applies many of the same concepts as IPM but

limits the use of pesticides to those that are produced from natural sources, as opposed to

synthetic chemicals. Integrated pest management (IPM) is a broad based ecological approach

http://en.wikipedia.org/wiki/Ecological


to agricultural pest control that integrates pesticides/herbicides into a management system

incorporating a range of practices for economic control of a pest. In IPM, one attempts to

prevent infestation, to observe patterns of infestation when they occur, and to intervene

(without poisons) when one deems necessary.

Insect pests are proven carriers of many known diseases and therefore pose a constant threat

to food manufacturers, food processing facilities, healthcare facilities and the hospitality

industry.

Steps for an Effective Integrated Pest Management Program:

In food processing environments, quality pest control is a must. A pest infestation can put

your product and your business’ reputation at risk because nobody wants to find something in

the product that’s not on the label. But pest management in such environments is also very

sensitive. Special precautions must be taken to keep pest control treatments from threatening

food safety. To better control pests while respecting a food plant’s sensitive environmental

needs, you need to apply the principles of integrated pest management (IPM).

IPM programs are successful for a simple reason. They recognize that pest management is a

process, not a one-time event, and that relying solely on chemical controls when so many

other tools are available is never the best solution. By addressing the underlying causes of

pest infestations – access to food, water and shelter – IPM can prevent infestation before

pesticides are even considered. In practice, IPM is an ongoing cycle of seven critical steps:

1: Inspection The cornerstone of an effective IPM program is a schedule of regular inspections. For food

processors weekly inspections are common, and some plants inspect even more frequently.

These routine inspections should focus on areas where pests are most likely to appear –

receiving docks, storage areas, employee break rooms, sites of recent ingredient spills, etc. –

and identify any potential entry points, food and water sources, or harborage zones that might

encourage pest problems.

http://en.wikipedia.org/wiki/Agricultural

http://en.wikipedia.org/wiki/Pest_control

http://en.wikipedia.org/wiki/Infestation


2: Preventive Action: As regular inspections reveal vulnerabilities in your pest management program, take steps to

address them before they cause a real problem. One of the most effective prevention measures

is exclusion, i.e., performing structural maintenance to close potential entry points revealed

during inspection. By physically keeping pests out, you can reduce the need for chemical

countermeasures. Likewise, sanitation and housekeeping will eliminate potential food and

water sources, thereby reducing pest pressure.

3: Identification: Different pests have different behaviors. By identifying the problematic species, pests can be

eliminated more efficiently and with the least risk of harm to other organisms. Professional

pest management always starts with the correct identification of the pest in question. Make

sure your pest control provider undergoes rigorous training in pest identification and behavior.

4: Analysis: Once you have properly identified the pest, you need to figure out why the pest is in your

facility. Is there food debris or moisture accumulation that may be attracting it? What about

odors? How are the pests finding their way in – perhaps through the floors or walls? Could

incoming shipments be infested? The answers to these questions will lead to the best choice of

control techniques.

5: Treatment Selection: IPM stresses the use of non-chemical control methods, such as exclusion or trapping, before

chemical options. When other control methods have failed or are inappropriate for the

situation, chemicals may be used in least volatile formulations in targeted areas to treat the

specific pest. In other words, use the right treatments in the right places, and only as much as

you need to get the job done. Often, the “right treatment” will consist of a combination of

responses, from chemical treatments to baiting to trapping. But by focusing on non-chemical

options first, you can ensure that your pest management program is effectively eliminating

pests at the least risk to your food safety program, non-target organisms and the environment.

You’ll also see higher pest control scores at audit time.


6: Monitoring: Since pest management is an ongoing process, constantly monitoring your facility for pest

activity and facility and operational changes can protect against infestation and help eliminate

existing ones. Since your pest management professional most likely visits your facility on a

bi-weekly or weekly basis, your staff needs to be the daily eyes and ears of the IPM program.

Employees should be cognizant of sanitation issues that affect the program and should report

any signs of pest activity. You don’t want to lose a day when it comes to reacting to an actual

pest presence.

7: Documentation: Since pest control can account for up to 20 percent of your total score, it’s imperative that

your IPM program is ready to showcase come audit time. Up-to-date pest control

documentation is one of the first signs to an auditor that your facility takes pest control

seriously. Important documents include a scope of service, pest activity reports, service

reports, corrective action reports, trap layout maps, lists of approved pesticides, pesticide

usage reports and applicator licenses.

To ensure that your IPM program reaches its potential, approach your relationship with your

pest management professional as a partnership. Open communication and cooperation

between you, your staff and your provider makes for a winning IPM program. The benefits

are fewer headaches, safer products and better audit scores.


COMMON INSECTS IN FOOD INDUSRTIES:

Common name

Identification

Typical

adult

lifespan

Almond moth

Forewings are light gray to brown with straight dark lines or

banding near outer portion of wing, hindwing is light gray to

beige with fringe of hairs on margin, wing tips are rounded

0.51-0.83 in (13-21 mm) wingspan

14 days

Mosquito

All mosquito species have one pair of scaled wings with a pair

of halteres. Mosquitoes have slender bodies with long legs.

While their size varies by species, most mosquitoes are smaller

than 15 mm in length and weigh less than 2.5 mg

7-10 days

House Fly

1/4 inch long: dul gray with 4 stripes on thorax; 4th wing vein

sharpley angled.

7-45 days

Household Ants

Workers are all the same size, small, 1/8 inch long, Dark brown

to shiny black, Petiole with 1 node, hidden by abdomen,

Thorax uneven in shape when viewed from side, Very strong

odor when crushed.

45-60 days

Rats

Body length of 7-9 inches, Coat of coarse shaggy brown hair,

Blunt noses, Tail around 6-8 inches long, Blunt ended capsule

shaped droppings approximately 3/4 inch in length.

23 months

http://www.doyourownpestcontrol.com/house-fly.htm

http://www.ipm.ucdavis.edu/TOOLS/ANTKEY/odorid.html

http://www.ipm.ucdavis.edu/TOOLS/ANTKEY/odorid.html


DEFENSE LINES IN INNOVATIVE BISCUITS (PVT) LTD PREVENTIVE ACTIONS:

1st Defense Line: In first defense line 20 bait stations are present along with

boundary wall of industry. 2nd Defense Line: In second defense line air curtains and buffer areas are used.

CORRECTIVE ACTIONS:

3rd Defense Line: In third defense line Mechanical traps, Glue boxes (40 boxes),

Electric fly killers (EFK) are included. 4th Defense Strategy: In this category we use permitted sprays (“ATTACK” and

“GAURDIAN” outside the buildings and "GUARDIAN PLUS” inside the buildings)

and spot killing.

TOOLS:

a) Glue Boxes

b) Bait stations

c) EFK’s(electric fly killer)

d) Cages

e) Sprays

A. GLUE BOXES:

One of the more common methods of mouse control is known as a mouse glue trap. These

sticky mouse traps are designed to be cost effective and low maintenance when compared

with more hands on methods such as the application of rodenticides. Because they are non-

toxic. Glue traps are made using natural or synthetic adhesive applied to cardboard, plastic

trays or similar material. Bait can be placed in the center or a scent may be added to the

adhesive by the manufacturer. Glue traps are used primarily for rodent control indoors. Glue

http://www.domyownpestcontrol.com/mouse-control-c-21_37.html

http://www.domyownpestcontrol.com/rodents-c-21.html

http://en.wikipedia.org/wiki/Glue

http://en.wikipedia.org/wiki/Paperboard

http://en.wikipedia.org/wiki/Bait_(luring_substance)

http://en.wikipedia.org/wiki/Scent

http://en.wikipedia.org/wiki/Manufacturer

http://en.wikipedia.org/wiki/Rodent


traps are not effective outdoors due to environmental conditions (moisture, dust), which

quickly render the adhesive ineffective. Glue strip or glue tray devices trap the mouse in the

sticky glue. . This is one option if you don't want to kill the rat. Keep in mind that a glue trap

can result in a frightened, angry rat that will attempt to bite whoever takes the glue trap

outdoors. Glue traps are often placed inside a box for that reason. Once the rat has been

caught in the glue, the entire box can be taken outdoors so that no one comes in contact with

the rat. Glue boxes contain a plastic sheet and a gel is pasted on it. The gel which is used is

known as ATRARAT. Glue boxes are checked every day and if any rat is present then it is

trapped in box

Number of Glue Boxes: 37 glue boxes are present in Innovative

B. BAIT STATION:

Bait stations are basically black box with a trap inside. Mice and rats never see it coming. The

bait box acts as harborage and safe haven for mice and rats, and this style of trap plays a

safety role when children and pets are present.

Location: Bait stations are present inside the boundary walls. Bait station are not present

inside the plant because a poison is placed inside it which attract the rats.

Number of Bait Station: 27 Bait station are present in Innovative.

C. ELECTRIC FLY KILLERS:

The electronic fly killer in the form of the electric fly trap works on principle that they use

light which is a major source of attraction for flies, mosquitoes and other related bugs and

insects. The electronic fly killer, as the name suggests works only when there is a source of

electricity which activates the electric fly trap. This electronic fly killer along with giving out

a specific scent for the flies and insects to get attracted to also has a high beam light which is

the most favorable source for flies. The moment the flies sit on the electronic fly killer, they

are glued down to the plate and starve to death there only. Some of the electronic fly killer

also features a slight electric current which is passed on to the electronic fly killer board. This

makes the elimination of the flies and insects faster and less painful. The moment the

electronic fly killer is switched off, the dead flies are collected in a tray attached to the

http://en.wikipedia.org/wiki/Moisture

http://en.wikipedia.org/wiki/Dust


electronic fly killer and can be disposed off easily. Some of these fly killer lamps also use

ultraviolet light to attract and kill the flies. This electronic fly killer is one of the best devices

for trapping flies, mosquitoes and other insects. The latest electronic fly killer is mainly made

out of stainless steel and is beautifully designed so that along with the utility factor, it also

adds to the décor of the room. They electronic fly killer is extremely efficient and is widely

used in offices, restaurants, home etc.

Number of EFK’s: There are present 22 EFK’s in Innovative.

LOCATION:

1. Sugar grinding area

2. Biscuit mixing section, in front of stairs

3. Biscuit mixing section, lift area

4. Biscuit mixing section, processing area

5. Biscuit cutting section, hand washing station

6. Biscuit cutting section, plant #1

7. Biscuit cutting section plant #3

8. Biscuit cooling section/chock-2 packing section

9. Biscuits packing section, near entrance

10. Biscuits packing section, near staff offices

11. Lock room- near plant stairs

12. Lock room- near outward stairs

13. Admin office

14. Dispatch section

15. Wafer sheet mixing section

16. Wafer sheet mixing section, change room

17. Wafer section, hand washing station

18. Wafer packing section

19. Packing material store

20. Electric workshop

21. Mechanical workshop


22. Molded chocolate section

D. CAGES:

A rat cage trap is a metal cage box-shaped device that is designed primarily to catch rats

without killing them. Food bait (not poisoned) is put in the cage trap. When an animal enters

the cage and moves toward the bait, the mechanism triggers and closes a door over the entry

point. The animal is caught alive and without injury. The animal can be transported and

released elsewhere or subsequently killed.

E. SPRAYS:

a) Attack

b) Gardian

c) Gardian plus

a. Attack:

In this active ingredient is Dichlorvos.it is sprayed on floors, lower parts of walls, around

baseboards or moldings, around door and window frames, in corners, in cracks or crevices, on

beds, behind or underneath objects, or within cabinets, cupboards, drawer spaces, closets, or

storage spaces, It is not sprayed in the production area. It kill flies, crawling insects, mosquito,

lizards.

b. Gardian:

In this active ingredient is Detta Methnin.it is sprayed on floors, lower parts of walls, around

baseboards or moldings, around door and window frames, in corners, in cracks or crevices, on

beds, behind or underneath objects, or within cabinets, cupboards, drawer spaces, closets, or

storage spaces, It is not sprayed in the production area. It kill flying and crawling insects.

c. Gardian Plus:

It is also sprayed in production area. It kill same insects as attack but it has no smell so it is

mostly sprayed inside the building e.g mixing areas, packaging areas, cooling areas

http://en.wikipedia.org/wiki/Bait_(luring_substance)


Insects found in 24 hours:

INSECT

EQUIPMENT

NO OF INSECTS

LOCATION Day1 Day 2

Mosquito

EFK

53 70 New Hall

24 29 Old Hall (Cutting)

Flies

EFK

1 3 New Hall


Ants

Glue Box


18 23 New Hall

Tiny bark beetles EFK, Glue Box 70 56 Old Hall (Cutting)

GAP ANALYSIS AT INNOVATIVE BISCUITS PVT. LTD REGARDING

INTIGRATED PEST MANAGEMENT GAPS OBSERVED POSSIBLE SOLUTIONS

Lids of gutter on main road near security

office are not closed properly that provide

breeding environment to mosquitos

Proper covering of gutters

Water standing and opened gutters before

quality assurance laboratory

Drainage system on road

Water driving pipes ends are filled with water

and not covered on main road from security

office

Proper covering of pipes or removal of

whater

Bait stations are filled with dust and not

properly cleaned

Grains should be changed as needed

Spraying only in main street and security

office and near generators area

Spraying at all around the processing hall

Most of Glue box are empty Placement of paper having glue on it

No mechanical traps at store and Mechanical traps at store and cutting section


OLD HALL

Main entrance door to cutting has holes and

gap upside the door

Gap covering by welding

Emergency exit of cutting section remain

open

Buffer area construction

At the entrance of packaging department, on

left side, hole for wire is not closed properly

Close the hole so that rodent cannot enter

Window no. 3 in packaging hall have hole

and dust

Cleaning if windows as needed

Gap in door in packaging hall near lift That door should be closed as there is no

need for that

No glue boxes at packaging section’s doors There are doors that are direct opened in

street so glue boxes are necessary

Area near lift in not cleaned that is hiding

place for insects

After cleaning, accessing door should be

locked as no need to open that

Gap in main enternce to chockalate section

from main street due to wire

There should be buffer area and wires should

be passed through proper ways

New Hall

In cutting section at plant no 4, 5 electrical

trays and pipes are not closed properly

Pipes should be closed as they allow entrance

of insects and pests

In cutting section, near conver no. 11,12,14

pipes are not closed

Pipes should be closed

In cutting section, near entrance door from

lab, wall has cracks

Wall cracks should be filled

Washing inside the cutting section Washing should outside processing area

Trays not washed Unwashed trays should be kept outside

processing area


Raw material on floor near pillars Repairing of floor or proper cleaning of floor

cracks

Window no 3 in cutting section is opened Windows should be closed as they have small

holes that cannot stop insects

Window no 20 in baking hall has no glass

and 2,3,5,23 are not properly closed

Windows should be closed

Emergency doors have holes and gaps in

packaging section

Gap should be filled with brush or any other

material

Uncovered hole in wall due to new plant in

new hall packaging section

Proper wall should be constructed or removal

of trays and proper closing of holes with

sheet

Door mostly remains opened and direct

opening in packaging section

There should be buffer area or it should

beauto closing door

Wafer Section

Gap in door and window used for conveying

goods in mixing section

Filling of gaps

5 holes in roof in mixing section Repairing of roof

Chocos Section

In mixing section, beneath stairs, hiding place

for insects is not cleaned

This place should be cleaned

2 holes and small gap in cutting section

entrance door

Gap should be removed

No buffer area Buffer area should be there


ASSIGNMENT # 2 Contents:

Role of fat, sugar, water and flour in biscuits.

ROLE OF FAT IN BISCUITS: Fat in the form of solid shortening, margarine, or butter; or in the liquid form of oil

contributes tenderness, moistness, and a smooth mouthfeel to baked goods. Fats enhance the

flavors of other ingredients as well as contributing its own flavor, as in the case of butter. In

baked goods such as muffins, reducing the amount of fat in a recipe results in a tougher

product because gluten develops more freely. Another tenderizing agent such as sugar can be

added or increased to tenderize in place of the fat. A small amount of fat in a yeast dough

helps the gluten to stretch, yielding a loaf with greater volume.

Shortening:

Shortening is 100 percent fat and is solid at room temperature. It is often made of

hydrogenated (solidified by adding hydrogen) vegetable oils, but sometimes contains animal

fats. The flakiness of pastry comes from solid fat such as shortening or lard rolled in layers

with flour. In some recipes for cookies or cake, shortening is creamed with sugar to trap air. A

lighter product will result. There are emulsifiers in shortening to help emulsify shortening and

liquid. This means that oil and water stay mixed together, creating an even distribution of

flavors and a consistent texture in batters and dough.

Butter:

Butter is made from cream and has a fat content of at least 80 percent. The remaining 20

percent is water with some milk solids. Butter imparts a good flavor without a greasy mouth

feel to baked goods because it melts at body temperature.

Margarine:

Margarine is made from fat or oil that is partially hydrogenated, water, milk solids, and salt.

Vitamins and coloring are usually added also. The fat or oil can be of animal or vegetable

origin. Margarine has the same ratio of fat to non-fat ingredients as butter (80:20), and can be

used interchangeably with butter.

Reduced fat substitutes:


Reduced fat substitutes have less than 80 percent fat. These do not work the same as butter or

margarine in baked goods, though some specially formulated recipes can be found on the

packages of these products. Fat free margarines also are available and contain no fat. These

margarines are best used as spreads.

Oil:

Oil is used in some muffin, bread and cake recipes. Oil pastry is mealy rather than flaky. To

substitute oil for butter or margarine, use 7/8 cup oil for 1 cup butter or margarine. If oil is

used in place of a solid fat for some cake recipes, the texture will be heavier unless the sugar

and egg are increased

ROLE OF FLOUR: Flour provides the structure in baked goods. Wheat flour contains proteins that interact with

each other when mixed with water, forming gluten. It is this elastic gluten framework which

stretches to contain the expanding leavening gases during rising. The protein content of a

flour affects the strength of a dough. The different wheat flour types contain varying amounts

of the gluten forming proteins. Hard wheat, mainly grown in the mid west of the U.S. has a

high protein content. Soft wheat, grown in southern U.S. has less protein.

Cake flour is a soft wheat flour that is 7.5 percent protein. The lower gluten content causes

products to have a tender, more crumbly texture that is desirable in cake.

All purpose flour is blended during milling to achieve a protein content of 10.5 percent. This

medium protein flour can be used for all baking purposes. If using all purpose flour in place

of cake flour in a recipe, substitute 1 cup minus 2 tablespoons all purpose flour for 1 cup cake

flour.

Whole wheat flour may be substituted for part of the white flour in yeast and quick bread

recipes, but the volume of the finished product will be reduced. Whole wheat flour contains

the nutritious germ and bran as well as the endosperm of the wheat kernel. Bran particles cut

through the gluten during mixing and kneading of bread dough, resulting in a smaller, heavier

loaf. If substituting a very coarsely ground whole wheat flour for all purpose flour, use 1 cup

plus 2 tablespoons whole wheat flour for every cup of all purpose flour. To substitute whole


wheat flour in a white bread recipe, use half whole wheat and half bread flour for the best

results.

Wheat germ, though not a flour, is often used in place of part of the flour in recipes for flavor

and fiber. Protein, vitamins, minerals, and polyunsaturated fats are concentrated in the germ

of grain kernels. Wheat germ, preferably toasted, can be used in place of up to 1/3 of the flour

in a recipe. The following non-wheat grain products are often used in baked goods. They are

rich in protein but most do not have the potential for developing gluten.

Rye flour is often used in combination with wheat flour for bread. Light rye flour can be

successfully substituted for 40 percent of wheat flour in a recipe without loss of volume.

Medium and dark rye flours should be limited to 30 percent and 20 percent, respectively, of

the total flour amount.

Triticale flour is a hybrid of wheat and rye. It has an average protein content higher than that

of wheat flour. In yeast bread dough, triticale flour has better handling properties than rye

flour because it will form gluten, but does not handle as well as wheat dough. For a good

quality dough, ferment yeast dough made with Triticale flour for a shorter period than wheat

flour dough.

Oat flour has relatively high protein content, 17 percent, but does not form gluten. Oat flour

can be substituted for as much as 1/3 of wheat flour in bread.

Corn meal is coarsely ground dried corn. Corn flour is more finely ground corn. Both corn

flour and corn meal contain 7-8 percent protein on a dry basis. Neither corn meal nor corn

flour will form gluten. A grainy texture in cornbread can be avoided by mixing the cornmeal

with the liquid from the recipe, bringing to a boil, and cooling before mixing with the other

ingredients.

Rice flour has about 6.5-7 protein and does not form gluten. For people who do not tolerate

gluten, rice flour is an acceptable substitute for wheat, barley, rye or oat flours. In baked

products, 7/8 cup of non-waxy rice flour can be used in place of 1 cup all-purpose wheat

flour. Soy flour contains 50 percent protein and is used primarily to boost the protein content

of baked goods. Soy flour cannot form gluten and does not contain starch. Its use in large

amounts affects the taste of baked goods and causes them to brown quickly. An acceptable


substitution is to take 2 tablespoons flour out of each cup of flour in a recipe and add 2

tablespoons soy flour.

ROLE OF SUGAR Sweeteners are one of the most important ingredients used in bakery foods. While there are

many different sweeteners available, A large variety of sugars can be produced by extracting

and purifying sugar from sugar cane and sugar beet. These sugars may differ in colour,

flavour, sweetness, and crystal size. For example, the molasses in brown sugar gives it a

different flavour and appearance compared to granulated white. Sugar can also be used in

both crystalline and liquid forms. All of these characteristics contribute to the variety of

functions performed by sugar in foods. Sugar not only makes foods taste sweet, it also has

many other functions.

Sensory Properties

Sweetness is generally the most recognized functional property of sugar. The preference for

sweetness is thought to be innate, appearing shortly after birth. Perception of the relative

sweetness of sugar depends on factors such as temperature, pH, concentration, presence of

other ingredients, and the difference in individuals’ ability to taste (e.g., detection threshold).

Sugar is an important contributor to flavor by interacting with other ingredients. Depending

on the food application, sugar has the unique ability to heighten flavor or depress the

perception of other flavors. In breads, for example, the resulting flavor typically is due to two

processes that involve sugar In bakery products, sugar is recrystallized as water is removed

during baking, resulting in a crisp texture. This crispness is increased by the effects of

browning. Two different reactions are responsible for crust browning: caramelization and the

Maillard reaction. Caramelization results from the melting of sugars to create a deep brown

color and new flavors. The yellow-brown colors that developing baked foods can be attributed

to the presence of sugar. Sucrose itself develops color through caramelization. In addition,

sugar can be broken down into its two monosaccharide units (glucose and fructose), which

can take part in the Millard reaction and add to browning. Sugar also contributes to the color

of preserves and jellies through its capacity to attract and hold water. By absorbing water

more readily than other components, such as fruit, sugar prevents the fruit from absorbing


water.

Sugar acts as an important tenderizing agent in foods such as baked products. During the

mixing process, sugar competes with other ingredients for water. In bread-making for

example, the affinity of sugar to bind to water will delay the development of gluten, a protein

in grains that is essential for maintaining a soft or tender product. Gluten strands, in general,

are highly elastic, and this property allows the batter to stretch under the expansion of gases.

Too much gluten formation, however, will cause the dough or batter to become rigid and

tough. When the correct proportion of sugar is added in the recipe.

Physical Properties:

The physical functions that sugar contributes to foods include its solubility in water, its ability

to lower the freezing point and raise the boiling point. Solutions of varying sugar

concentrations are important in many food applications, including the production of jellies

and jams. Freezing point depression is an important property in ice creams, frozen desserts,

and freeze-dried foods to ensure the development of fine crystal structure and product

smoothness.

Microbial (Food Preservation and Fermentation)

Sugar plays an important role in extending the shelf life of bakery products. Sugar can bind to

water molecules, slowing moisture loss and preventing staleness in baked goods. In addition,

the glucose/ fructose mixture in invert sugar present in jams and jellies helps to inhibit

microbial growth and, later, spoilage.

Fermentation, an extremely important process in the baking industry, is fuelled by sugars.

Sugars are used to activate yeast for fermentation. The type and amount of sugar added can

increase the dough yield and softness of bread by altering the rate of fermentation. When a

hard crust bread is desired, sugars are either omitted or used in lower quantities. In this case,

the yeast is activated by sugars formed when starch is broken down by enzymes present in the

flour. Sugars remaining after fermentation contribute to the overall flavour, colour, and

texture of the final product.


ROLE OF WATER:

Water is a basic ingredient in baking. It would be impossible to produce biscuits without

water in some form. It facilitates mixing of ingredients and other steps of processing. There

are certain functions of water which include:

• It makes possible the formation of gluten.

• It wets and swells the starch.

• It assists in controlling the temperature of dough a through adding cold or warm water

the temperature of the dough can be regulated.

• It dissolves salts, suspends and distributes non-flour ingredients uniformly.

ASSIGNMENT #3

Contents:

• 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:

Belts and Hopper are cleaned.

Mixer is cleaned.

Hopper is cleaned.

Dough feeding conveyer is cleaned.

Die is cleaned or changed accordingly.

Roller of die are cleaned with air pressure.

Stiching of belt is checked.

Floor is cleaned.

Temperature of room and dough are checked.


Activities (SOPs) at oven section:

Oven temperature is adjusted.

Wasted is cleaned and stacked into yellow trays.

Steel belt is cleaned with dough so that product bottom do not get contaminated by

burnt residues of biscuits, baked before.

Stiching of cooling conveyer belt are checked.

Rollers are cleaned.

Activities (SOPs) at stacker:

Diameter of stacker rows are adjusted.

Rework trays are cleaned.

Activities for packaging section:

Reels of packaging machines are checked.

Waste/ rework trays are cleaned.

Packaging machine is cleaned for any residues of already packed product.

Operational activities

Cutting started at 7:50 AM

Time when first row came out of oven = 7:59 AM

Time when product reached at stacker = 8: 06 AM

Packaging material issued at 8:00 AM

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

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

ASSIGNMENT # 4

• CPM of cutter and temperature of dough

• CCPs in biscuit plant

• Calculate baking loss

CPM of cutter is 110 and temperature of dough was 21 C̊.

CCPs in Biscuit Plant:

a) Dough temperature

b) Room temperature

c) Metal detector

d) Contamination of foreign material

e) Cutter arrangement

f) Knife sharpness


Calculate baking loss:

To calculate baking loss we weighed unbaked and baked weight of 10 biscuits.

Sr.# Unbaked weight

(grams)

Baked weight

(grams)

Baking loss %

1 76.86 67.46 12.23 %

2 75.16 66.6 11.32%

3 74.4 63.73 14.38%

4 75.5 65 13.9 %

5 76.8 66.86 12.93%

6 79.6 67.76 14.8%

7 75 65 13.33%

8 75.76 65.3 13.80%

9 75.46 65.3 13.46%

10 79 68.26 13.59%

11 77.3 65.46 15.3%

12 73.86 63.9 13.48%

13 78.53 67.63 13.8%

14 75.13 64.16 14.60%

15 75.73 64.7 14.56%

16 76.2 65.1 14.56%

17 77.33 65.23 15.64%

18 75.2 64.4 14.36%

19 75.80 64.66 14.69%

20 78.13 66.6 14.75%

21 78 67 14.10%

22 76 65 14.47%

23 73.13 62.63 14.36%

24 79.53 66.4 16.51%

25 75.76 64.53 14.83%


Formula

Baking loss % = weight before baking – weight after baking x 100 / weight before baking

Result: Average baking loss is 14.15 %.

ASSIGNMENT # 5

Contents:

• Calculate biscuit being produce at cutter and packed at packaging machines.

• Calculate difference being waste

• Calculate rate of production per hour

• Plant capacity for 11 hours shift

• Calculate actual floor waste and rework with total wastage percentage

• Find machine stoppage reasons , wastage of wrapper and stoppage time

BISCUIT BEING PRODUCED AT CUTTER

CPM = 110

No of rows = 17

Biscuits produced in one minute = 110 X 17 = 1870 biscuits

Biscuits produced in one hour = 1870 X 60 = 112200 biscuits

BISCUIT BEING PACKED AT MACHINES

Speed of machines of H/R = 155

Biscuits in one packet = 10

Biscuits packed in one minute = 155 X10 = 1550 biscuits

Biscuits packed in one hour = 1550 X 60 = 93000 biscuits

Speed of machine of T/P = 100

Biscuits in one packet = 3

Biscuits packed in one hour= 3 X 100 X 60 =18000 biscuits

Total packed biscuits = 93000 + 18000 = 111000 biscuits

WASTAGE PERCENTAGE

Production = 112200 biscuits

Packed biscuits= 111000


Wasted = 112200 – 111000 = 1200 biscuits

Wastage percentage = 1200 X 100 /112200 = 1.06 %

RATE OF PRODUCTION

Biscuits in one ctn = 10 X 6 X 24 = 1440 biscuits

Production in one hour = 111000 /1440 = 77.08 carton / hour

PLANT CAPACITY FOR 11 HOURS SHIFT

Maximum cutter speed = 170 CPM

No of rows = 17

Biscuits in one hour = 17 X 170 X 60 = 173400 biscuits

Biscuits in 11 hour = 172400 X 11 = 1907400 biscuits

H/R ctn in 11 hours = 1907400 / 1550 = 1230 ctn / shift

FLOOR WASTE AND REWORK WASTE FROM 8:00 AM TO 2:30 PM

Sr # Wastage type Floor Rework

1 Wastage at cutting 3.4 kg N.A

2 Packaging waste 335 g 600 g

3 Stacker wastage 783 g 36.69 kg

4 Wastage by QA 35 g N.A

5 Machine wastage 100 g 4 kg

6 Wastage due to dough problem N. A N.A

7 Wastage at oven section 20 g 5.060 kg

8 Wastage due to product mishandling N.A N.A

9 Wastage at stacker belt end 4.450 kg 80.38 kg

Total 9.123 kg 126.73 kg

Total production = 2575.584 kg

Wastage = 9.123 + 126.73 = 135.853 kg

Wastage percentage = 135.853 X 100 / 2575.584 = 5.27 %


MACHINE STOPPAGE REASONS:

1. Camera out

2. Panel out

3. Stamp problem

4. Slow labor

5. Magazine / feeding problem

6. Reel change

7. Over heat / low heat of sealers

8. Gap in processing

WRAPPER WASTAGE

Total packets packed in one hour = 120 X 60 = 7680

Total wasted packets = 39

Wastage percentage = 39 X 100 / 7680 = 0.507 %

STOPPAGE IN ONE HOUR

Working time = 60 mints

Stoppage = 7 mints

Stoppage percentage = 7 X 100 / 60 = 11.66 %

ASSIGNMENT# 6

Contents:

• Calculate batch consumption time

• Calculate number of biscuits per batch

• Ctn / batch

• If we support to operate plant at 400 CPM then how many packaging machines are

required if the speed of machines in 100

Batch consumption time is 19.40 minutes

Mixer emptying time = 1:06 mints

Trolly moving and loading time = 0:29 mints

Time on conveying belt = 20 seconds


Time from mould to oven = 30 seonds

Baking time = 2:24 mints

Cooling time = 4:53 mints

No of biscuits per batch:

CPM = 230

No of rows = 25

Biscuits in one batch = 230 X 25 X 19.40 = 111550 biscuits

Ctn / Batch:

Biscuits in one ctn = 12 X 24 X 18 = 5184 biscuits

Ctn production per batch = 111550/5184 = 21.51 ctns

If we support to operate plant at 400 CPM then how many packaging machines are

required if the speed of machines in 100

CPM = 400

Rows = 25

Production in one mint = 400 X 25 = 10000 biscuits / mint

Biscuits packed by one machine = 100 X 12 = 1200/ mint

No of machines = 10000 / 1200 = 8.33 machines

8 machines will work at 100 speed and one machine will work at 33 speed to pack production

at 400 CPM at assumed zero wastage.


ASSIGNMENT # 7

Contents:

• Find baking loss for jumboo

• Behavior of product in different zones of oven

• No of burners in zones and color of flame in zones

• Count number of burners during standby mode and working mode on biscuit line no 5

BAKING LOSS FOR JAMBOO

Sr no. Unbaked weight of 4 pcs Baked weight of 4 pcs

1 9.7 grams 8.31 grams





Average 9.8 grams 8.33 grams

Average weight before baking = 9.8 grams

Average weight after baking = 8.33 grams

Baking loss percentage = 9.8 – 8.33 X 100 / 9.8 = 15 %

Zone behavior and no of burners

Sr

no

Type Temperature Burners Flame

color

Product behavior

Adjusted Working

1 Direct 102 C̊/98 C̊ 86 C̊/90 C̊ 20 Blue Puffing

2 Indirect 165 C̊ 172 C̊ 1 Yellow Puffing

3 Indirect 215 C̊ 228 C̊ 1 Yellow Puffing and baking

4 Indirect 211 C̊ 211 C̊ 1 Yellow Baking

5 Indirect 215 C̊ 212 C̊ 1 Yellow Baking

6 Indirect 214 C̊ 204 C̊ 1 Yellow Baking and coloring


Number of burners during standby mode and working mode on biscuit line no 5

Zone

no.

Actual

burners

Burners

STB

Temperature

(C̊) STB

Burners

W

Temperature

(C̊) W

Top Bottom Top Bottom Top bottom Top Bottom Top Bottom

1 9 10 6 6 122 142 6 9 138 146

2 11 13 10 13 193 145 10 13 187 146

3 8 12 6 10 185 150 6 10 198 145

4 8 8 7 6 198 134 7 6 175 137

5 8 7 6 4 206 123 6 4 185 133

6 8 7 8 0 189 100 8 7 190 110

7 8 8 0 0 150 112 5 6 155 120 *STB= standby mode W= working mode

ASSIGNMENT # 8

Contents:

• Ingredients of wafer sheet and cream and make a batch

• Problems in wafer sheet due to mixing problems

• Make twelve parts of a plain sheet and find difference in different parts of sheet.

• Make twelve parts of tree laired cream sheet and find cream ratio in different parts of

sheet

INGRIDIENTS AND BATCH MAKING.

Ingredients for wafer sheet and batch mixing procedure

• Starch

• Flour

• Water

• Soda

• Salt

• Lecithin


• Corn oil

In mixer added water. Then added soda, salt and lecithin. Added flour gradually

and mixed it for 8 minutes and shifted to storage tank

Ingredients for wafer cram and batch mixing procedure

• Fat

• Sugar

• Color

• Flavor

• SMP powder

• Whey powder

• Starch

• Glucose / Dextrose

Added fat in mixer. Then added SMP powder, whey powder 6 kg sugar, glucose and

starch.

Added color flavor and grinded sugar. Mixed till holes formation in cream

PROBLEMS IN WAFER SHEET DUE TO MIXING CORRECTIVE ACTION

Water and lecithin are not measured properly that cause thick and thin problem in

wafer sheet.

Underdeveloped and overdeveloped are dependent of mixing time that cause problem

in wafer sheet,

If batter is overdeveloped then more gluten will develop that cause chipping of sheet.

If batter in underdeveloped then the corner of sheet will not be formed.

If sheet weight is less then less water is used about 5 liters less.

If sheet weight is more, then more water is added.

If sheet is soft then we use less soda, if sheet is hard then more soda is added.

If sheet is hard then more corn oil is used.

If sheet is being separate after baking then amount of soda is reduced.

If sheet is soft then more salt is added to strengthen the gluten network.


If sheet is sticking with oven plate then more lecithin is added

MAKE TEWELVE PARTS OF A PLAIN SHEET AND FIND DIFFERENCE IN

DIFFERENT PARTS OF SHEET.

There are 65 plates of oven so we took one reading of each plate by making 12 parts of each

sheet as mentioned above. All the readings are in grams.

Plate

no.

Part

1

Part

2

Part

3

Part

4

Part

5

Part

6

Part

7

Part

8

Part

9

Part

10

Part

11

Part

12

1 2.6 2.5 2.4 2.9 2.6 2.6 2.5 3.1 2.6 2.4 2.6 2.8

2 2.5 2.4 2.4 2.6 2.3 2.2 2.2 2.4 2.6 2.4 2.5 2.6

3 2.6 2.5 2.4 2.5 2.4 2.3 2.4 2.5 2.5 2.5 2.6 2.6

4 2.6 2.5 2.6 2.7 2.8 2.3 2.3 2.5 2.8 2.4 2.4 2.7


5 2.1 2.3 2.2 2.4 2.2 2 2.2 2.2 2.2 2.1 2.2 2.3

6 2.1 2.1 2.3 2.4 2 2.1 2.2 2.3 2.2 2.1 2.1 2.3

7 2.6 2.5 2.7 2.9 2.6 2.2 2.3 2.6 2.2 2.4 2.5 2.5

8 2.2 2.1 2 2.3 2.1 2 2.1 2.1 2.6 2.1 2.1 2.2

9 2.2 2.2 2.1 2.1 2.2 2.4 2.1 2.1 2.2 2.1 2.1 2.3

10 2.2 2.3 2.2 2.2 2 2.1 2.3 2.1 2.1 2.1 2 2.2

11 2.2 2.3 2.2 2.3 2.2 2.4 2.1 2.2 2.3 2.4 2.4 2.3

12 2.1 2.2 2.4 2.5 2.1 2.2 2.3 2.5 2.4 2.2 2.2 2.5

13 2.2 2.1 2.2 2.2 2.2 2.1 2.2 2.3 2.6 2.1 2.2 2.3

14 2.7 2.7 2.8 3 2.8 2.9 2.8 2.7 2.6 2.5 2.6 2.9

15 2.2 2.1 2.1 2.3 2.4 2.4 2.3 2.4 2.5 2.3 2.3 2.2

16 2.1 2.1 2.2 2.5 2.2 2.2 2.3 2.5 2.3 2.2 2.3 2.5

17 2.1 2.2 2.3 2.4 2.1 2.3 2.2 2.5 2.2 2.1 2.2 2.4

18 2.4 2.2 2.3 2.4 2.2 2.2 2.4 2.2 2.5 2.1 2.2 2.5

19 2.5 2.3 2.4 2.5 2.2 2.2 2.2 2.4 2.4 2.1 2.4 2.7

20 2.5 2.5 2.8 3.1 2.3 2.5 2.6 2.8 2.5 2.4 2.5 3

21 2.6 2.4 2.7 2.6 2.4 2.4 2.4 2.1 2.7 2.2 2.5 2.4

22 2.2 2.2 2.3 2.4 2.1 2.2 2.3 2.4 2.3 2.2 2.2 2.4

23 2.2 2.2 2.3 2.4 2.2 2.2 2.2 2.3 2.1 2.2 2 2.3

24 2.4 2.2 2.2 2.5 2.2 2.2 2.1 3.3 2.3 2.2 2.2 2.5

25 2.2 2.1 2.1 2.4 2.3 2.3 2.2 3.3 2.2 2.3 2.3 2.8

26 2.7 2.4 2.5 2.8 2.6 2.3 2.3 3.8 2.6 2.4 2.6 3

27 2.7 2.5 2.6 2.9 2.5 2.3 2.3 2.7 2.6 2.4 2.6 2.8

28 2.2 2.4 2.5 2.3 2.4 2.3 2.3 2.4 2.4 2.2 2.4 2.7

29 2.2 2 2.1 2.1 2.2 2.1 1.9 2 2.1 2.1 2.1 2.3

30 2.2 2.1 2.1 2.2 2.1 2.1 2.1 2.1 2.2 2.1 2.1 2.3

31 2.3 2.2 2.3 2.4 2.1 2.1 2.2 2.2 2.3 2.1 2.3 2.5

32 2.2 2 2.2 2.2 2.1 2 2.1 2 2.2 2.2 2.3 2.1

33 2.4 2.2 2.3 2.4 2.3 2.3 2.3 2.4 2.2 2.2 2.3 2.5


34 2.7 2.5 2.6 2.9 2.4 2.2 2.3 2.7 2.6 2.4 2.5 3

35 2.1 2.2 2.2 2.4 2.1 2.2 2.2 2.3 2.2 2.2 2.3 2.3

36 2.7 2.5 2.5 2.8 2.6 2.3 2.3 2.6 2.3 2.4 2.5 2.8

37 3 2.6 2.6 2.8 2.9 2.4 2.3 2.5 2.7 2.5 2.5 2.9

38 2.5 2.2 2.2 2.3 2.4 2.1 2.2 2.2 2.6 2.1 2.2 2.2

39 2.4 2.5 2.4 2.4 2.2 2 2.1 2.1 2.2 2.1 2.2 2.2

40 2.1 2.1 2.2 2.4 2.1 2.1 2.2 2.2 2.1 2.1 2.1 2.2

41 2.1 2.1 2.2 2.5 2.1 2.1 2.2 2.3 2.2 2 2 2.3

42 2.9 2.6 2.3 3.1 2.6 2.5 2.4 2.8 2.9 2.7 2.7 2.8

43 2.6 2.4 2.6 3 2.5 2.4 2.4 2.7 2.6 2.5 2.5 2.9

44 2.3 2.3 2.4 2.4 2.3 2.3 2.1 2.2 2.3 2.2 2.3 2.1

45 2.2 2.2 2.2 2.2 2.1 2 2 2.2 2.2 2.1 2.2 2.2

46 2.3 2.2 2.3 2.2 2.3 2 1.8 1.9 2.1 1.9 2 2

47 2.2 2.2 2.4 2.5 2.2 2.1 2.3 2.5 2.3 2.1 2.3 2.7

48 2.4 2.2 2.4 2.7 2.4 2.3 2.3 2.4 2.4 2.3 2.4 2.8

49 2.1 2.1 2 2.2 2.1 2 1.9 2 2.1 2.1 2.3 2.6

50 2.2 2 2.2 2.3 2 2 2.1 2.2 2.2 2.1 2.2 2.4

51 2.3 2.1 2 2 2.3 1.9 2.1 2.2 2.3 2.2 2.2 2.2

52 2.1 2.1 2.2 2.3 2 2.1 2.1 2.2 2.1 2.1 2.1 2.2

53 2.2 2.2 2.2 2.6 2.2 2.1 2 2.3 2.3 2.1 2.1 2.9

54 2.5 2.4 2.2 2.7 2.3 2.1 2 2.4 2.2 2.2 2.1 2.7

55 2.4 2.4 2.2 2.2 2.3 2.1 2.3 2.2 2.3 2.3 2.2 2.4

56 2.6 2.4 2.5 2.9 2.4 2.4 2.3 2.7 2.5 2.3 2.5 2.9

57 2.3 2.2 2.2 2.5 2.4 2.3 2.3 2.4 2.4 2.2 2.3 2.4

58 2.1 2 2.1 2.4 2.1 2.1 2.1 2.2 2.1 2 2.5 2.4

59 2.3 2.1 2.1 2.4 2.1 2.2 2.3 2.4 2.1 2 21 2.4

60 2.3 2.3 2.3 2.4 2.2 2.1 2.3 2.4 2.2 2.2 2.1 2.4

61 2.2 2.1 2.2 2.3 2.1 2 2.1 2.2 2.1 2 2.2 2.1

62 2.2 2.1 2.3 2.4 2.1 2.1 2.1 2.2 2.3 2.1 2.1 2.3


63 2.4 2.4 2.2 2.2 2.4 2.2 2.2 2.3 2.4 2.4 2.3 2.4

64 2.1 2.2 2.1 2.2 2.2 2.1 2.1 2.2 2.4 2.4 2.3 2.3

65 2.1 2.1 2.1 2.4 2.1 2.1 2.2 2.4 2.1 2.1 2.2 2.4

There was a difference in different parts of one plate and it ranged to maximum difference of

0.7-1.2 grams so mechanical department reviewed the depth / gap between every plate of

oven of plant no 3.

MAKE TEWELVE PARTS OF THREE LAIRED CREAM SHEET AND FIND

CREAM RATIO IN DIFFERENT PARTS OF SHEET.


Same sampling method was used for creamed sheet. We took ten readings to minimize error

in data. All the readings are in grams.

Sr# P 1 P 2 P 3 P 4 P 5 P 6 P 7 P 8 P 9 P 10 P 11 P 12

1 21.3 27.1 26.1 22.8 19.9 24.9 24.4 21.3 22.5 24.8 23.8 22.6

2 21.7 27.6 27.5 24.7 24.4 28 27.1 23.7 23.2 29.5 27.8 25.3

3 21.5 27.3 28.1 24 22.6 29.2 29.8 26.9 22.3 27.5 26.9 25.1

4 24.5 30.2 28.9 25 24.1 28.2 27.3 24.3 25.6 29.1 26.7 23.8

5 19.4 23.8 21.8 17.4 24.4 25.5 22.7 20.7 23.3 24.5 22.2 18.9

6 20.8 25.1 25.2 21.4 21.3 26 25.9 22.9 23.8 26.1 23.8 22.5

7 19.1 26 25.2 20.9 21.9 26.1 25.5 21.8 22.7 28.4 26.5 21.3

8 22.1 25.3 24.5 21.1 25.2 28.8 27.9 24 26 27.1 27 23

9 20.9 28 28.1 23.5 18.5 25.7 26.4 22.4 21.5 27.4 25.8 21

10 19.2 24.4 24.4 22.2 19.6 24.2 23.5 21.7 23.8 28.9 27.1 23.3 *P1, P2, P3, P4, P5, P6, P7, P8, P9, P10, P11, P12 are parts of sheet according to cutting scheme.

Due to weight difference in different parts of sheet adjustments of cream machine were made

till the error was minimum.

ASSIGNMENT # 9

Contents:

• Find chocolate for one piece and no of pieces formed by one sheet.

• Find cream for one piece.

• Find plain figure weight.

• Weight of sheet, cream and chocolate for one carton.

CHOCOLATE FOR ONE PIECE AND NO OF PIECES BY ONE SHEET

Horizontal cut = 10

Vertical cut = 18

No of fingers formed by one sheet =10 X18 = 180 pieces

10 pieces weight before chocolate enrobing = 15.5 g


10 pieces weight after chocolate enrobing = 39.2 g

Chocolate consumed by 10 pieces = 23.7 g

Chocolate consumed by one piece = 2.37 g

CREAM FOR ONE PIECE

Weight of 3 plain sheet = 134.1 g

Weight of one finger = 134.1 / 180 = 0.745 g

Weight of 3 creamed sheet = 318.6 g

Weight of one creamed finger = 318.6 / 180 = 1.77 g

Cream consumed by one piece = 1.77 – 0.745 = 1.025 g

WEIGHT OF CHOCOLATE, CREAM AND SHEET FOR ONE CARTON

No of fingers in one carton = 36 X 36 = 1296

Cream for one piece = 1.025 g

Cream for one carton = 1.025 X 1296 = 1328.4 g = 1.3284 kg

Chocolate for one piece = 2.37 g = 0.00237 kg

Chocolate for one carton = 0.00237 X 1296 = 3.0715 kg

Weight of one uncreamed finger = 0.745 g

Weight of sheet for one carton = 0.745 X 1296 = 965.52 g

= 0.96552 kg

ASSIGNMENT # 10

Contents:

• Baking loss for wafer sheet

• Batch weight and total dry weight after baking of one batch

• Wastage and average carton per batch if one carton contain 0.96552 kg of sheet

• If one shift working time is 10.5 hours then how many batches are required and how

many carton are produced


BAKING LOSS

Container weight = 40 g

Batter weight of three sheets with container = 498.2 g

Batter weight without container = 498.2 – 40 = 458.2 g

Batter weight for one sheet = 458.2 / 3 = 152.7 g

Weight of one sheet after baking = 44.53 g

Baking loss = 152.7 – 44.53 X 100 / 152.7 = 70.8 %

TOTAL DRY WEIGHT OF BATCH

Weight of one batch = 65.5 kg

Baking loss = 70.8 X65.5 / 46.374 kg

Dry weight = 65.5 – 46.374 = 19.126 kg

WASTAGE AND AVERAGE CARTON PER BATCH IF CARTON CONTAIN 0.96552

KG OF SHEET

Actual production by one carton = 18 ctn

Calculated production = 19.126 / 0.96652 = 19.78 ctn

Weight of one carton (sheet) = 0.9655 kg

Packed weight of sheet = 0.9655 X 18 = 17.379 kg

Wastage = 19.126 – 17.379 = 1.747 kg

Wastage % = 1.747 X 100 / 19.126 = 9.1%

IF ONE SHIFT WORKING TIME IS 10.5 HOURS, HOW MANY BATCHES ARE

REQUIRED AND HOW MANY CARTONS ARE PRODUCED

Average sheets by one batch = 430 + 426 /2 = 428 sheets / batch

Batch consumption time = 19.53 mints

Shift working time = 10.5 hours = 630 mints

No of batches = 630 / 19.53 = 32.25 batches

No of sheets in one shift = 32.25 X 428 = 13803 sheets

No of sheets after creaming (3 plies) = 13803 = 4601 sheets (3 plies)


No of fingers production in one shift = 4601 X 180 = 828180 fingers

Fingers in one carton = 1296 finger

No of carton production in one shift = 828180 / 1296 = 639.02 carton / 10.5 hours shift

SUGGESTIONS / FEEDBACK:

General: 1) Products name and trademark logo should be unique and have no resemblance with

other as it has bad effect on consumer.

2) Resign ratio is high in industry and main reason for resign are duty hours, there should

be three shifts to reduce resigns.

3) Less co-operation between QA department and Production department

4) Height of cutting section in new hall should be reduced for better cooling.

5) Cutting section should be provided temperature gun instead of estimating temperature

with hand.

6) Quality inspector is controlling weight variation at cutting then he should be

responsible for weight variation throughout the process line

7) Quality Assurance inspectors should prefer online checking at packaging machine

instead of end carton.

8) Floors in mixing should be sanitized at least one time in a day.

9) Dustbins should be cleaned immediately when filled.

10) Emergency exit doors should not be locked.

11) There should be glue boxes at every outer door processing hall.

12) Every person in mixing should have health fitness certificate and have no

communicable disease.

13) There should be first aid training in industry every year.

14) There should be a medical service for any emergency. 15) Safety gloves and safety shoes should be provided to oven operators. 16) Mess should be improved and timetable should be maintained.


Wafer section: 1) There should be a hand drying facility with hand washing facility.

2) Temperature of mixing section is not controlled.

3) RPM of mixer at plant no.1 are less than other three mixers but mixing time is same

that should be calibrated.

4) Workers should wear mask during floor sieving.

5) Mixer should be cleaned after every batch instead of evening.

6) Temperature monitoring devices of oven are not calibrated for oven of plant no. 2,3

and 5 in wafer section.

7) Wafer cutting machines should be covered to avoid contamination.

8) Drinking of water should not allow in mixing and there should be a sign for not

drinking area.

9) Drinking water facility should be with hand washing facility in wafer section.

10) Lecithin should be measured accurately.

11) Filtration cloth should be used for filtration of batter to avoid spreading gun blockage.

12) After washing, floor should be sanitized at least one time in a day.

13) SMS should be added 1-2 minute before completing mixing instead to adding at the

start of mixing.

14) Water in wafer mixing section is not clean.

15) By managing labor or increasing labor we can increase production of wafer about 35

% at same equipment

Biscuits sections: 1) There should be hand washing facility in hew hall and chocos hall. 2) Windows should have auto closing mechanism for batter IPM. 3) Wrapper for packaging should not be stacked to floor in store. 4) All the doors (both parts of door) should have auto closing mechanism because doors

are opened for long period of time and workers should be trained to always keep doors

close. And there should be a sign on door showing that doors are auto closing. 5) Windows of old hall should be cleaned after a specific period.


6) Windows of new hall are opened that should not be opened. 7) There should be emergency light in chocos hall. 8) For belt stitching there should be a stitching machine as most of gaps are due to belt

stitching. 9) Cooling conveyer rollers may harm to workers as the packaging machines are beneath

cooling belt. 10) Cutter of packaging machines should be changed or repaired.

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.

We worked in different departments of industry and in every department we worked with a

new set people. We worked in quality department and filled quality control and quality

assurance reports according to sample specifications. We also worked in production

department of old hall, new hall, wafer section and chocos hall. Quality assurance department

lacks the quality inspector so sometime cutting and oven section in monitored by one quality

inspector and he cannot fulfill his duties because if he is controlling weight variation at

cutting then he should be responsible for weight variation throughout the process line. Quality

Assurance inspectors should prefer online checking at packaging machine instead of end


carton. Production can be increased by managing labor by their training about GMPs of

industry.

References

[1] http://innovativebiscuits.com/

[2] Baking science and technology 4th Edition, E.J. PYLER AND L.A. GORTON

[3] Technology of biscuits, crackers and cookies, 3rd Edition, Duncan Manley

[4] http://www.marthastewart.com/265820/essential-baking-tools

[5] http://www.quakeroats.com/cooking-and-recipes/content/baking-101/welcome-to-baking-

101/baking-equipment.aspx

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