SUMMER TRAINING REPORT

BHAGWATI FOODS PVT LTD, KANPUR

SUBMITTED TO:-BHAGWATI FOODS PVT LTD

KISAN NAGAR, SACHENDI KANPUR, 209304

SUBMITTED BY:-
MOHD SALMAN MOHSIN
M.Tech(Food Technology)
HBTU,Kanpur

SCHOOL OF CHEMICAL TECHNOLOGY

Department of Food Technology
Harcourt Butler Technical University
Kanpur,Uttar Pradesh

1
 ACKNOWLEDGMENT

I am thankful to Mr. Hariram Agrawal (Chairman, Bhagwati Foods) who

provided me Opportunity in his industry to gain knowledge, also I would like to
thank Mr. Pankaj Agrawal ( Factory Incharge) & Mr. Sudheer Gupta (M.D).

I am extremely grateful to Mr.Brijesh Shukla(Production Officer,Britannia) &

Mr. Ankit Shukla (Quality Officer, Britannia) who provided me guidance in my
each and every step & cleared my doubts every time. They also provided me
valuable scientific as well as conceptual Knowledge which will definitely help
me in my future work.

I am very thankful to Mr. Rajesh Chauhan (Lab Incharge), Miss Akanksha

Chakrawarti (Lab chemist),Miss Manisha Maurya(Lab chemist),Mr.Ankit
Chauhan(Lab Chemist) for his kind and friendly support in the lab. Finally, I
thank one and all who have helped me directly or indirectly for the Purpose.

2
 Index

Content Page.No

1. Introduction 4-5

2. Use of ingredient and its role 6-8

3. Laboratory 9-26

4. Mixing 27-39

5. Processing 40-45

6. Function of oven 42

7. Cooling and Packaging 44-47

8. Full process of Biscuits making 48

9. Use of Sieves standard 50

10. Daily Quality Index 51

11. Conclusion 52

3
 INTRODUCTION OF BRITANNIA INDUSTRY

The story of one of India's favourite brands reads almost like a fairy tale. Once upon a
time, in 1892 to be precise, a biscuit company was started in a non-descript house in
Calcutta (now Kolkata) with an initial investment of Rs. 295. The company we all
know as Britannia today.

The beginnings might have been humble-the dreams were anything but. By 1910,
with the advent of electricity, Britannia mechanized its operations, and in 1921, it
became the first company east of the Suez Canal to use imported gas ovens.
Britannia's business was flourishing. But, more importantly, Britannia was acquiring
a reputation for quality and value. As a result, during the tragic World War II, the
Government reposed its trust in Britannia by contracting it to supply large quantities
of "service biscuits" to the armed forces. As time moved on, the biscuit market
continued to grow and Britannia grew along with it. In 1975, the Britannia Biscuit
Company took over the distribution of biscuits from Parry's who till now distributed
Britannia biscuits in India. In the subsequent public issue of 1978, Indian
shareholding crossed 60%, firmly establishing the Indians of the firm. The following
year, Britannia Biscuit Company was re-christened Britannia Industries Limited
(BIL). Four years later in1983, it crossed the Rs. 100crores revenue mark. On the
operations front, the company was making equally dynamic strides. In1992, it
celebrated its Platinum Jubilee.

In 1997, the company unveiled its new corporate identity - "Eat Healthy, Think
Better - and made its first foray into the dairy products market. In 1999, the
"Britannia Khao, World Cup Jao" promotion further fortified the affinity consumers
had with 'Brand Britannia' Britannia strode into the 21st Century as one of India's
biggest brands and the pre-eminent food brand of the country. It was equally
recognized for its innovative approach to products and marketing: the Lagaan Match
4
was voted India's most successful promotional activity of the year 2001 while the
delicious Britannia 50-50Maska-Chaska became India's most successful product
launch. In 2002, Britannia's New Business Division formed a joint venture with
Fonterra, the world's .

Second largest Dairy Company, and Britannia New Zealand Foods Pvt. Ltd. Was
born. In recognition of its vision and accelerating graph, Forbes Global rated
Britannia 'One amongst the Top 200 Small Companies of the World', and The
Economic Times pegged Britannia India's 2nd Most Trusted Brand. Today, more
than a century after those tentative first steps, Britannia's fairy tale is not only going
strong but blazing new standards, and that miniscule initial investment has grown
by leaps and bounds to crores of rupees in wealth for Britannia's shareholders.

BHAGWATI FOODS PVT. LTD.

Bhagwati Foods Pvt. Ltd., Sachendi , Kanpur was established in 1 March 2007.
Bhagwati Foods Pvt Ltd, Kanpur co-packer unit of Britannia industries Ltd. Mr.
Hariram Gupta is the Director of the plant. Many types of product made by Bhagwati
foods ltd . Like as Butter cookies, Butter elaichi , Marie gold, Tiger glucose.

It located on Akbarpur Road about 25 km away from Kanpur city. The

monthly Production of Biscuits is 2278 Tones. The plant commenced
production in March 2007.

At Bhagwati foods Pvt. Ltd. has an effective manpower 176 which includes
both line and staff authorities. At Tiger plant is 3.23 tones per hour every
day and Marie plant is 1.83 tones per hour every day. The achievement of
plat includes International Standard for Organization (ISO).

5
 Use of ingredient and its role

Biscuits making ingredient can be classified two categories.

A. Major ingredient.

1. Wheat flour.
a) It is primary ingredient for baking.
b) Wheat flour used for biscuit making should be made from a soft wheat variety.
c) Protein content should be low.
d) The moisture absorption of flour to make a dough should not be more than 60%.
e) The flour should make dough with more extensibility but less resistance.
f) Development of gluten complex.

2. Refined Bleached Deodorised (RBD Palm oil).

a) It gives the sweating properly.

b) It gives the prow string through the aeration.

c) H.V.O. given the aeration in the dough.

d) It gives sytobit & given the crispiness.

3. Sugar.
a) Main function of sugar in biscuits to use as sweetness.

b) Sugar is set of rancidity control the shrinkage & spread.

c) It helps in enhancing the flavor of biscuits. & helps in retention of moisture.

d) It helps in providing colour ; caramelization & maillard type browning. It acts as a

preservative also.

e) A part from this sugar maintains moisture of dough.

f) It gives to brown colour.

6
 4. Invert Syrup.
Invert sugar syrup is pale coloured sweetener prepared by the acid hydrolysis/
enzymatic hydrolysis of a solution of white refined sugar. Inver syrup contains
equal proportions of the invert sugar glucose and fructose. It has wide application
and is particularly useful where high concentrations of invert sugars are fructose.
The crystal-inhibiting characteristics and humectants properties mean that the shelf
life of many products can be extended by the use of invert syrup in product
formulations. It is an equimolar mixture of glucose & Fructose. It is obtained by
acid or enzymatic hydrolysis of sucrose.

a) It gives the colour.

b) Maintain the dough PH.

c) Freezing point depressant.

d) Provide body and cohesiveness.

B. Minor ingredient.

1. Salt.
a) It is a flavour & taste enhancer.
b) It exerts desired strength & tightening effect on dough.
c) It is preservative & taste.
d) Hording of gluten.

2. SMBS.
a. Dough conditioner cut the long chain of gluten.
b. It gives the extensibility and elasticity.
c. It gives the extensibility power.
d. It cut the sit bond of gluten.
e. Increased the machine ability.

7
 3. Skim milk powder.
a) Give the browning colour on top surface of area.
b) Taste of the final product.
c) Gives the protein.

4. Lecithin.
a) It natural antioxidant at con reduce.
b) It is emulsifier.

5. Citric Acid.
It is providing colour to syrup.

6. Sodium Bicarbonate.
a) It maintains the pH of final products.
b) To given the crumb colour (inner side of biscuits colour).
.

7. Ammonium Bicarbonate.
NH4CO3- NH3I + CO2+ H2O
a) Expansion of volume.
b) It is help to maintain the dough ph (7.5-80).
c) It is aerating aren’t.

8. Sol bake.
It is emulsifier and provides stability of product.

9. Ferrous Fumarate.
Have more elemental iron in it.

10. Calcium Carbonate.

It is provide calcium to final product.

11. Flavour.
a) It is used for unique flavour.
b) It enhances the taste.
8
 Laboratory
A. Testing of Raw material.

1. Wheat Flour

a) Moisture.

1. Moisture content is the amount of moisture present in the wheat flour.

Apparatus:-

Petridish , hot air oven.

Procedure :- Take a clean & dry petri dish and weight it.

Weight 10gm. Of sample and pour it in petridish.

Put the dish in oven at 135oC for 5 hrs.

Take out the petri dish and cool it in dessicator and again weight it.

Formula used:- Weight of PD + sample Before Drying –

Moisture% = Weight of PD + sample After Drying * 100
Weight of sample taken

9
2. Ash.
1. It gives the information the % of bran & foreign materials present in the

flour.

2. Less moisture indicates more ash content.

3. Ash is a mineral content of the flour.

Principle:

1. Total ash is the inorganic residue remaining after incineration of sample.

2. It also indicates the grade or extraction rate of flour.

Apparatus:

Silica dish, Balance, Muffle furnace, Dessicator etc.

Procedure:- Take the weight of crucible

Take 10 gm sample in crucible

Put the crucible in muffle furnace at 550°C +/_-30°C for 4 hours

Cool it in dessicator for 30 min.

Now take weight of the crucible

Formula used:- Weight of crucible + sample Before Drying –

Ash Content = weight of crucible + sample After Drying *100 *100
Weight of sample taken * (100 – Moisture %)

10
c) Acid Insoluble Ash.

Principle:-

1. It gives idea about added mineral matter dirt, sand etc.

2. It indicates the silica content. This is mainly due improper cleaning of wheat

prior to milling.

3. Higher quantities of acid insoluble ash are injurious to health.

Apparatus :- Muffle furnace, Water bath and dessicator.

Reagant :- 5N HCl

Procedure:- Take the ash content in crucible.

Add 25ml of 5N. HCl solution to the ash containing crucible.

Filter it in a flask with whatman filter paper no.42

Heat it till bubbling

Wash the filter paper with water until paper was free from acid.

Take the filter paper with the residue and put it in H.A.O. for 3 hours at 135+/-2 °C

Transfer it to muffle furnace for 3 hours at 550+/-20 °C

Cool the crucible in desiccator and weight it.

Formula used:- Ash Content = 100(W2 – W) x 100

W1 – W (100 - M)

W = Weight of empty crucible.

W1 = Weight of crucible + sample before drying.

W2 = Weight of crucible + sample after drying.

M = Moisture content of sample.

11
d) Alcoholic acidity
Flour which stored long time, under goes various types of deterioration, which in turn

gives high value for alcoholic acidity this is accelerated in presence of high moisture,

temperature etc.

Principle:-

Alcoholic acidity to the combined acidity as we get by.

1. Hydrolysis of fat by Lipase in free fatty acid.

2. Hydrolysis of protein in to amino acid by proteolysis enzymes.
3. Acidity due to presence of certain acid, salts etc.

Reagents:-

1. Neutral Ethyl Alcohol- 90 % (volume).

2. Sodium hydroxide solution.

3. Phenolphthalein indicator.

Procedure:- Prepare 90% ethanol solution.

(45ml ethanol + 5ml distilled water)

Put few drops of phenolphthalein in the solution.

Add 7- 9 gm. of sample to flask containing solution.

Make the solution neutral by titrating it with 0.05N NaOH till pink colour appears.

Keep it for 2 hours untouched

Filter it in a test tube using filter paper no. 1

Take 10ml of filtrate obtained in a flask.

Add few drops of phenolphthalein indicator in it.

Titrate it with 0.05N NaOH, till pink colour is obtained as end point.

12
 Formula used :- Ash insoluble ash = 24.52 x V x N
Sample weight

V = Volume of NaOH used.

N = Normality of NaOH used.

e) Sedimentation value

Principle:-

This principle is based on more sedimentation value of flour, higher will be gluten

content and the flour will be more suitable for bakery product.

Procedure:- Take 50ml of bromophenol indicator in a measuring cylinder.

Weight 3.20gm. of sample and pour it in the cylinder.

Shake it for 5 min.with putting in a mechanical shaker.

Then add 25ml of lactic acid to the cylinder and again shake it for 5 min.

Then leave it for settlement for 5 min.

Note down the reading how much flour is settled

f) Gluten

Determination of Gluten:-

Gluten is a protein which develops the flour is mixed with water the gliadine and

Glutenin protein forms the elastic structure called Gluten.

Principle:-

Gluten is the most important gives idea about the flour strength.

13
 Procedure:- Take 25gm of wheat flour

Make dough of it using 12ml water.

Dip the dough in a beaker full of water for 1 hour.

Now wash it with running tap water so that all the starch is been removed.

Wash it till a rubbery structure is obtained.

Make a ball of gluten obtained and put it in previously weight dish.

Put the petridish in H.A.O. for 4 hours at 105°C

Cool it in dessicator and weight it.

Formula used:- Gluten Content = Weight of petridish + gluten before drying –

Weight of petridish + gluten after drying

2. Refined Bleached Deodorised

A. TBHQ (Tertiary Butyl Hydroxy Quinine):-

Procedure:- Take 5ml of sample in a test tube.

Add 5ml. of methanol to the test tube and shake it.

Add 5 ml of Diethyl Amine and shake well

If red colour appears TBHQ is present in the oil.

If red colour not appears. TBHQ test fails. Such oil is rejected.

B. Free Fatty acid :-

Procedure:- Take 90% of ethyl alcohol solution (45ml ethanol + 5ml distil water)
Add few drops of phenolphthalein indicator.

Titrate it with 0.05N NaOH , till pink colour is seen.

Add 15 – 20ml of sample in the flask containing neutral.

Put on hot plate till boiling and add few drops of phenolphthalein.

Again titrate it with 0.05N NaOH.

Formula used :- F.F.A = 28.2 x V x N

Sample weight

14
 N = Normality of NaOH used. , V = Volume of NaOH used.

C. Peroxide Value :-

Procedure:- Take 2 – 3gm sample in a flask.

Prepare 3:2 solution (acetic acid: chloroform)

Add 25 ml of above sol. and 1ml of saturated Potassium Iodate.

Add 35ml of water along with 1ml of 1% starch solution, which acts as indicator.

Titrate it with 0.002N Sodium Thiosulphate.

 End point is appearance of white colour or disappearance of blue colour.

 Also prepare a blank solution with this. Blank solution is prepared without using
sample.

Formula used:- Peroxide Value = 1000 x (S - B) x N

Sample weight

4. Lawn Sugar

a) Moisture Content

Procedure:- Take a clean& dry petridish and weight it.

Weight 10gm. of sample and pour it in petridish.

Put the Petridish in Oven. at 105oC for 3 hrs.

Take out the petridish and cool it in dessicator and again weight it.

Formula used:- Weight of PD + sample Before Drying –

Moisture% = Weight of PD + sample After Drying * 100
Weight of sample taken

15
b) Suspended Particle Test

Procedure:- Take 40gm of sugar as a sample.

Dissolve it in 200ml of water.

See any suspended particle, dust, unwanted matter floating.

 If the solution is clear then the sugar is accepted for further use.
 If suspended particles are seen in solution. Such sugar is been rejected.

5. FLAVOUR

a) Specific Gravity

Procedure:- Take the weight of specific

gravity bottle.

Fill the sample in the specific

gravity bottle fully and then
press the stopper.

Again take the weight of

gravity bottle.

16
6. CONDENSED MILK

Acidity Test

Procedure:- Take 5 – 7gm of sample in a

flask.

Mix in 100ml luke warm water

of 45oC and cool the mixture.

Titrate it with 0.05N NaOH,

till pink colour is obtained.

Add few drops of phenolphthalein

as an indicator.

Formula used:- Acidity = 9xVxN

Sample weight

7. BUTTER

Acidity Test

Procedure:-
Take 5 – 7gm of sample in a
flask.

Mix in 100ml luke warm water

of 45oC and cool the mixture.

17
 Add few drops of phenolphthalein
as an indicator.

Titrate it with 0.05N NaOH, till

pink colour is obtained.

Acidity = 9xVxN
Formula used :- Sample weight

8. Yeast

a) Moisture.

1. Moisture content is the amount of moisture present in the wheat flour.

Apparatus:-

Petridish, hot air oven.

Procedure:- Take a clean& dry petridish and

weight it.

Weight 10gm. Of sample and pour it in

petridish.

Put the dish in oven at 105oC for 3

hours.

Take out the petridish and cool it in

desiccator and again weight it.

18
Formula used:- Weight of PD + sample Before Drying –
Moisture% = weight of PD + sample After Drying * 100
Weight of sample taken

b) Dough Raising Capacity.

Procedure:-
Take 50-55ml of water and add 4gm
yeast and 2gm grind sugar in it.

Make dough of 100gm maida using

the above water solution.

Place it in a dry beaker and measure

the height of it.

For 1 hour put the beaker into

fermentation room.

Measure the increase in height of

dough.

Formula used:-
DRC = B – A x 100

A = Initial height of dough.

B = Height of raised dough.

19
(Testing of Final Product)

a) Moisture.

1. Moisture content is the amount of moisture present in the biscuit.

Apparatus:-

Petridish, hot air oven.

Procedure:-
Take a clean& dry petridish and
weight it.

Weight 10gm. Of sample and pour it in

petridish.

Put the dish in oven at 105oC for 4

hours.

Take out the petridish and cool it in

desiccator and again weight it.

Weight of PD + sample Before Drying –

Formula used:-
Moisture% = weight of PD + sample After Drying * 100

Weight of sample taken

b) Ash.

. Principle:- Total ash is the inorganic residue remaining after incineration of sample.

It also indicates the grade or extraction rate of biscuit.

Apparatus:- Silica dish, Balance, Muffle furnace, Desiccator etc.

20
 Procedure:-
Take the weight of crucible

Take 10 gm sample in crucible

Put the crucible in muffle furnace

at 550°C +/_-30°C for 4 hours

Cool it in desiccator for 30 min.

Now take weight of the crucible

Weight of crucible + sample Before Drying –

Formula used:- Ash Content = weight of crucible + sample After Drying *100 *100

Weight of sample taken * (100 – Moisture %)

c) Acid Insoluble Ash.

Principle:-

1. It gives idea about added mineral matter dirt, sand etc.

21
 2. It indicates the silica content. This is mainly due improper cleaning of wheat

prior to milling.

3. Higher quantities of acid insoluble ash are injurious to health.

Apparatus:- Muffle furnace, water bath and desiccator.

Reagent:- 5N HCI

Procedure:-
Take the ash content in crucible.

Add 25ml of 5N. HCl solution to the

ash containing crucible.

Heat it till bubbling.

Filter it in a flask with whatman filter

paper no.42

Wash the filter paper with water until

paper was free from acid.

Take the filter paper with the

residue and put it in H.A.O. for 3
hours at 135+/-2 °C

Transfer it to muffle furnace for 3

hours at 550+/-20 °C

22
 Cool the crucible in desiccator and
weight it.

Formula used:-
Ash Content = 100(W2 – W) x 100
W1 – W (100 - M)

W = weight of empty crucible.

W1 = weight of crucible + sample before drying.

W2 = weight of crucible + sample after drying.

M = moisture content of sample.

d) Alcoholic acidity

Flour which stored long time, under goes various types of deterioration, which in turn

gives high value for alcoholic acidity this is accelerated in presence of high moisture,

temperature etc.

Principle:- Alcoholic acidity to the combined acidity as we get by.

1. Hydrolysis of fat by Lipase in free fatty acid.

2. Hydrolysis of protein in to amino acid by proteolysis enzymes.
3. Acidity due to presence of certain acid,salts etc.

Reagents:-

1. Neutral Ethyl Alcohol- 90%(volume).

2. Sodium hydroxide solution.

3. Phenolphthalein indicator.

23
 Procedure:- Prepare 90% ethanol solution.
(45ml ethanol + 5ml distil water)

Put few drops of phenolphthalein in

the solution.

Make the solution neutral by

titrating it with 0.05N NaOH till pink
colour appears.

Add 7- 9 gm. of sample to flask

containing solution.

Keep it for 2 hours untouched.

Filter it in a test tube using filter paper

no. 1

Take 10ml of filterate obtained in a

flask.

Add few drops of phenolphthalien

indicator in it.

Titrate it with 0.05 N NaOH till pink

colour is obtained as end point.

24
 Ash insoluble ash = 24.52 x V x N
Formula used:- Sample weight

V = Volume of NaOH used.

N = Normality of NaOH used.

(Testing of Packaging Materials)

1. C.B Boxes:

Analytical Characteristics:-
 GSM (gram/m2)
 For gsm take 10cm2 sample and take its weight.
 Dimension (length, width & height)
 No. of Futes
 Fute Height
 Moisture
 Compression Strength

General Characteristics:-

 Colour
 Declaration of
a) Mfg. Address
b) Stacking Norms
c) Net Weight
d) Wholesale Pack
 Print Matter & Quality
 Fabrication / Lamination
 Dammage & Foreign Odour

25
2. Laminates:
 GSM
 Dimension
 Sensory Evaluation of Laminate (Colour etc.)

3. HM bags/ Polybags:
 GSM
 Dimension
 Total Ash

Calculation:- GSM of wrapper = Weight of sample * width unit2 length

Count per kg = 1000 * Cut of length* width
GSM

4. Dimension:

 Length, Width & Height

5. Flute Height

 Measured from 3 inch mark

 X metre multiplied by 0.396

(Standards of different varieties of Britannia Biscuits)

S No. Variety Moisture % Total A.I.A% Fat % Acidity%

Ash%

1 Marie Gold 1% 1% 0.10% 10.9 0.1

2 Tiger Glucose 1.75% 1% 0.10% 13 0.1

3 Britannia 50-50 1.50% 1% 0.10% 19 0.1

4 Good day 1.50% 1% 0.10% 22 0.1

26
 Mixing
(Ingredients used in Marie Gold)

Ingredients
1. Wheat Flour(Maida)
2. Sugar Solution
3. Invert Syrup
4. RBD Palm Oil
5. Sol bake Paste
6. Salt
7. Whey Powder + Lactose Solution
8. Sodium Bicarbonate
9. Ammonium bicarbonate
10. Calcium bicarbonate
11. Ferrous Fumarate
12. Potassium Iodate
13. SMBS Solution (10%)
14. Vitamin Premix - 7
15. Flavor SBU -24
16. Flavor AMMG 23
17. Essence Mexico
18. Dust
19. Water
20. Datum 118 M.B

27
 (Ingredients used in 50-50)

Ingredients

1. Wheat Flour
2. Lawn Sugar
3. Invert Syrup
4. RBD Palm Oil
5. Solbake Paste
6. Salt
7. M.sugar
8. Sodium Bicarbonate
9. Ammonia
10. SMBS solution
11. Lactic Acid
12. Sponge
13. Dust
14. Flavour Vanilla
15. Flavour CR4
16. Flavour MMI

28
 Working Recipe of 50-50
(SPONGE)
Wheat Flour
Lawn Sugar
Invert Syrup
RBD Palm Oil
Compressed Yeast
Sodium bicarbonate
Water
Note :- Fermentation time for Sponge is 18-24 hours.

(PREMIX)
Maida
Lawn Sugar
Compressed Yeast
Enzyme Papain
Enzyme Neutrase
Enzyme Fungamyl
Citric Acid
Acid Calcim Phosphate
Water
Enzyme Penzea BG

29
 Note :- Fermentation time for premix is 45 min to 1 hr 15 min.

(FINAL DOUGH)
Wheat Flour (Maida)
Lawn Sugar
Invert Syrup
RBD Palm Oil
DATEM 118 MB
Salt
Sodium bicarbonate
Ammonium bicarbonate
Lactic Acid
SMBS 10% Soln
M. Sugar
Butter Flavour
Process dust
Water
Palmolein Oil for Spray

Note:- Fermentation time for Dough is 20-25 min.

30
 (Ingredients used in Tiger)
Ingredients

1. Wheat Flour(Maida)
2. Lawn Sugar
3. Invert Syrup
4. RBD Palm Oil
5. DMG Paste
6. Salt
7. Glucose Solution
8. Sodium Bicarbonate
9. Ammonium bicarbonate
10. SMP (Skimmed Milk Powder)
11. Ferrous Fumarate
12. SMBS Solution (10%)
13. Flavour T.G
14. Flavored Dairy Milk
15. Vanilla Flavour Powder
16. M.Sugar
17. Process dust
18. Lecithin Paste
19. Water
20. Folic acid

31
 (Ingredients used in Good day butter)
Ingredients
1. Wheat Flour(Maida)
2. Sugar Crystal
3. Invert Syrup
4. Butter Pasteurised
5. Palm Oil
6. Datem (1:1) Water
7. Lecithin Paste
8. DMG(1:1)
9. WMP
10. Refined Salt
11. Sodium bicarbonate
12. M.Sugar
13. Ammonium bicarbonate
14. Butter Flavour Powder
15. Flavour BUG 15001 GDN
16. Flavour BUG 15758 GDN
17. Flavour GMP 545 GIVAUDAN
18. Process dust
19. Water

32
 (Preparation of Solbake Paste)

Take 60 kg Solbake powder

into tank and heat it up to
63 - 65°C.

Keep the stirrer and heater

on till Solbake melts.

Then add 90 kg. RBD and

mix them properly and
sieve them with 24 mesh
sieve.

Now add 12 kg. Of water

previously sieved from 100
mesh sieve.

Mix them properly till

uniform paste is formed.

Transfer to container and

allow to cool before use.

33
 (Preparation of P. Iodate)

Take 500 ml Water + 12 gm

P. Iodate

Standard for above is 1ml

water + 0.24 gm P. Iodate

P. Iodate is ready.

Use 10 ml With Flavour

AMMG-23

(Preparation of Lecithin Paste)

(Lecithin: palm oil = 1:3)

Take 90 kg. Palm Oil & heat

& then add 30 kg lecithin

Allow it to cool

34
 Stir the above for 30 mins

Lecithin is now ready to be

used

(Preparation of Glucose)

5Kg Glucose + 5 kg Water

Mix the Above Properly

Glucose is ready

35
 (Preparation of Condensed Milk Spray)

Take 30 ltrs. Water & add 8

ltrs. Condensed Milk.

Add 4 kg Invert Syrup to

above .

Add 80 ml caramel Colour

& add 40 ml AMMG-23.

Milk Spray is ready for 8

batch.

(Preparation of M. Sugar)

59 Kg Sugar + 1 kg flavour
(Vanilla) in a trolley.

Mix them properly and

hold the Above for 48
hours before use.

M. Sugar Is Prepared.

36
 (Preparation of Invert Syrup)

Take 386.5 ltrs. Of water in

a tank and heat up to 50oC.

Add 900kg sugar to the

water and raise temp. To
105oC.

Add citric acid solution

(2.1 kg in 3.5ltr. water) and
raise temp. To 114oC.

When temp. reaches switch

off the heater and keep
running stirrer for 30 min.

Take the sample in lab for

brix checking. (77+/- 1)

If brix is okay then allow to

cool it for 30 min.

Transfer to storage tank.

37
 (Preparation of sponge for 50-50)

Take 5 ltr. of water and add

170gm of yeast to it.

Now add 170gm invert

syrup, 2.22kg palm oil,
110gm soda, 5 ltr water.

Mix at high speed for 2 min.

Then add 20 kg maida to it.

Mix for 3 -5 min. At high

speed.

(Preparation of premix for 50-50)

Take 3ltr. Water and add

1.83 kg yeast to it.

Pour 4ml fungamile in

mixer, add 3.7 kg sugar
and prepared yeast
solution.

Mix for 2min. At high

speed, then add 43gm
papin, 10gm neutrogen.

38
 Make sol. of 300gm MACP
and 40gm citric acid in 1 ltr.
Water.

Add the solution to mixer

along with 35 ltr. Of water.

Properly mix and empty it

in trolley.

39
 Processing
When the dough is been prepared from mixer, after that it has been held for
some time before use. Then the dough is transferred to the hopper from where
different rollers start working on it convert the dough is converted into form of
sheets by applied pressure from different rollers.

When the sheets are been formed, it is then cut into square type shape of equal
sides with the help of cutters. Then the cut sheets are placed one over other and
again further pressure is applied on them with help of rollers to convert them
into smooth sheets. Each roller has its own role, in changing the thickness of the
dough sheet.

When the dough is passed from final rolled then it is passed through moulder
where the sheets are been cut into required shape and size according to the
biscuit requirement.

Then after cutting into desired shapes from moulder, it is transferred to the
baking oven, where different temperatures act on it and the biscuit is been baked
and gets the required taste and colour. After that, it is cooled on cooling belt and
then packed into different packaging material.

Dough transferred Converted into sheets Converted into thin

to hopper. and cut with cutters. smooth sheets.

Cooling on belt Transferred to baking Cut into desired shapes

and packaging. zone for baking. with help ofmoulder.

Sheeter:-

40
Rotary moulder:

The dough to be moulded is fed into the hopper and a forcing roller forces the
dough into the moulding roller made out of gun metal, uniformly engraved and
coated with food grade Teflon. Excess dough is cleared with a knife, which is
held by a holder made from tool steel, to ensure uniform filling.

An adjustable rubber roller conveying the discharge web presses it uniformly

against the moulding roller for perfect transfer of moulded pieces from the
moulding roller on to the web.

The purpose of three drives is, speed of the forcing roller influences the density
of dough forced in to the moulding cavity. The speed of the die roller influences
the production speed. The discharge web speed influences the shape of the
biscuits produced along the web or across the belt.

41
 Function of Oven

The oven body consists:-

This is a multi-zone indirect fired biscuit oven suitable for general purpose
biscuit baking. This oven is divided into a number of independent zones each
comprising a combustion chamber with burner, circulating fan, turbulence fan,
and the associated duct work leading the banks of radiator tubes.

Radiant heating system:-

The products of combustion are recalculated through 102mm, diameter tubes
above and below the band. The gases in the radiator tubes are negative pressure
to ensure that the products of combustion cannot contaminate the goods in the
event of leakage. This system gives maximum to atmosphere, the remainder to
the combustion for re-heating.

Construction:-
The oven body consists of steel steam tight tunnel with appropriate divided
zones along with heating chambers and stainless steel expansion joints are

42
provided in order to eliminate the expansion of the oven sections. The
inspection windows are provided for inspection of the baking goods during the
process.

Heating Chambers:-
The complete chambers will be insulted from outside and fully automatic
oil/gas burners shall be fitted to produce required heat and temp shall be
controlled by automatic temp control fitted to the main control panel. The
dynamic balanced stainless steel fans/ blowers are provided to re- circulate the
heat and to increase the efficiency to the plant with the help of appropriate
electric motors.

Baking System:-

The baking takes place by heat radiators located under and above the wire mesh
band. The closed circulation system having slight vacuum so that the
combustion gases cannot enter into the baking zone. The moisture inside the
baking zone should be controlled by separately by another blower having proper
damper controller.

Insulation:-

The complete oven will be covered with 8” or 10” thick mineral wool from top,
bottom and the sides to preserve heat loss.

Dive & conveyor band:-

Appropriate A. C or Dynamo D. C Drive is being fitted to drive the Z- 47

articulate wire mesh bond on two rollers provided on not end of baking oven.

Electrical:-

43
Auto – electric control panel is provided along with safety devices to operate all
electric motors, drives and also to control temperature to maintain required
uniform heat at each baking zone by thermostatically auto temp controller .

Working of different zones:-

 Zone 1 & 2 are for Puffing.

 Zone 3 & 4 are for Muffing.

 Zone 5 to 7 are for Colouring.

Note :- The oven placed in the factory is 256 feet long and 1.2 metre broad.

Cooling and Packaging:-

Cooling conveyor :- From oven delivery the product is taken in to a
series of conveys where It& losses the last traces of moisture. The product is
usually turned over & back again during its journey to ensure even cooling
throughout & the total process takes one & a half times the oven bake time.

Construction:-

44
Cooling conveyor is made in a modular construction of 2.5 metres. Long and
connected together to form the required length the supporting side channels are
fabricated from 3mm thick M.S. sheet.

Idle rollers are spaced at 750mm apart on conveying direction and 1700mm on
the return direction. All the idle rollers are of 48mm.

Di mounted on 6004 ZZ deep groove ball bearings with grinding finish and hard
chrome plated for hygienic conditions. As you know very well practically about
the dropping of oil from the cloth due to rutting of cloth against tie angles when
producing high fat biscuits. To minimize this we replaced the all the angles also
with idle rollers. This might costs little extra, but you can maintain hygienic
conditions at working area. Drive drums are toes no’s of 22mm dia. and
projections are made on the surface of drums to minimize slip or covered with
friction grip rubber tape. Manual tensioning and tracking are provided. You can
rely only on feeder table to stack the oil sprayed biscuits which does not require
more travel after oil spraying.

Stacking Machine:-

45
 Packaging

Packaging is done in following criteria’s:-

 Packages should protect & preserve the product that is attractive enough’
to catch the eye & that describes the product adequately.
 Packages not to shake about during transit causing breakage.
 Packages need to be airtight .to stop the product taking up moisture from
the atmosphere & become soft.
 The Package gives consumer information & about ingredients.
 It should also indicate when the product must be used by & give some
nutritional information about the product as well.

SETTING OF CROSS PUSHER:-

 This adjustment is carried out with jaws hot (about 180oC) and knife
(cutter) removed.

46
  Never remove the anvil from the lower jaw. It is accurately set in our
factory.
 Tighten the screw F lower jaw.
 Position the crimp jaw in tangency.
 The lower crimp jaw is fixed .all adjustment are to be made on the upper
jaw.

CROSS PUSHER’S INITIAL POSITION:-

The initial position of cross pusher should be such that gap A between cross
pusher and adjustabil guide will be 2 to 3 mm. and gap b will be 1 to 2 mm.
adjust the gap between guide equals width of the biscuit+3mm.

CROSS PUSHER’S FINAL POSITION:-

The final position of cross pusher should be such that feeding conveyor rod
should be able to carry the product and also product should not foul with front
rod.

CUT OFF LENGTH ADJUSTMENT:-

This adjustment serves to feed more or less material during the machine cycle.
Depending on the length of the product t o be wrapped.

 Adjustment to be carried out during machine running and all rollers in

open condition.
 To decrease cut off length turn knob in clockwise direction.
 To increase cut off length turn knob in anti-clockwise direction.
 Turn the knob till PKL meter shows the values given.

To control on broken generation

47
Broken generation play a very important Role in biscuits industries. More
broken generation means less production. Recycle of broken generation
involves.

 Wastage of electric.
 Wastage of money.
 Wastage of man power.
 Wastage of time.
Full process of Biscuits making

For each variety of Biscuits a specific mixing sequence and procedure are
adopted. Various chemical reactions involved, and final dough characteristics
required are considered before formulation of mixer operations procedure.
Different type of mixer with different blade configurations and variable motor
are used. Proper mixer as well as proper mixing plays a vital in biscuit making.
That is why it is said that mixing, it “ Heart of biscuits making there are type of
mixers generally used for mixing purposes.

 Horizontal mixer.

 Vertical spindle mixer.

48
 Sieve Standards
Sno. Name Of the Ingredients Mesh No Of the sieve
1 Wheat flour/Starch/Rice Flour 40 mesh (min 24)
2 Whole Wheat Flour 30 Mesh (24)
3 Suji (Rava) 16 mesh
4 Toasted Ragi / Soya Flour 24 Mesh
5 Invert Syrup 40 mesh
6 Chemicals During Mixing 16 mesh
7 Process Dust broken Low fat Varieties-16 mesh
High Fat varieties- 12 mesh
8 Palm Oil 60 mesh (min 24)
9 Butter 24 mesh
10 Liquid Glucose 60 mesh (when Dissolved in
water)
11 Liquid Glucose Min. 16 mesh (Direct Sieving)
12 GMS Powder 24 mesh
13 Lecithin Fat 24 mesh
14 Colour Solution, Flavour, Citric acid 100 mesh (min 60 mesh)
Potassium Iodate, SMBS
15 Condensed Milk 40 mesh (if dissolved in water)
24 mesh (if directly sieved)
16 Honey 24 mesh
17 Inactive yeast Powder 24 Mesh
18 Malt Extract, Apple Juice Concentrate 16 mesh
19 Cocoa Powder 16 mesh
20 Skimmed milk Powder, Coconut Milk Powder 40 Mesh (for solution)
24 mesh (for direct sieve)
21 White Choclate, Compound Choclate ,Cocoa 100 mesh
mass
22 Water 100 mesh
23 Other Chemicals 24 mesh

49
 Daily Quality Index-DQI
CBB (Corrugated Board Box):-
CBB coding
CBB Taping
Head Space
CBB Busting
VBB Liners
Pouch Quality:-
Pouch Tightness
Sealing
Burst/Tear
DQI :- Pack Weight
Pack Tightness
Pack Coding
Pack Seal
Broken
Product Quality :-
Colour
Dimension
Flavour / taste
Bite
Appearance

50
 CONCLUSION

During the training period I learnt a lot & the training concrete shape to my
little knowledge about biscuit manufacture. I gained a lot in terms of practical
knowledge about the problems faced in the industry.

In Bhagwati Foods Pvt. Ltd. Company, the major emphasis is on the quality
‘of raw materials, finished product. The raw materials greatly influence the
quality of finished product. In order to ensure that the raw materials used in
production are of good quality the company has laid down a set of specification
for each of them. The standardization & revision of raw materials specifications
are done time to time.

I have also learnt to work in a team in coordination with others the training, has
a big impact on my perception about the working of an industry.

51
 References

 Mr. Brijesh Shukla (Production Manager, Britannia industry Ltd.)

 Mr. Ankit Shukla (Quality Officer, Britannia industry Ltd.)

 Mr. Pankaj Agrawal (Factory Manager, Bhagwati Foods Pvt Ltd)

 Mr. Rajesh Chauhan (Lab Incharge, Bhagwati Foods Pvt. Ltd.)

 Miss Akanksha Chakrawarti ( Lab Chemist, Bhagwati Foods Pvt.

Ltd.)

 Miss Manisha Maurya ( Lab Chemist, Bhagwati Foods Pvt. Ltd.)

 Mr. Sumit Verma ( Lab Chemist, Bhagwati Foods Pvt. Ltd.)

52