Professional Documents
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Os Nirapara Final PDF
Os Nirapara Final PDF
Os Nirapara Final PDF
Submitted to the
MAHATMA GANDHI UNIVERSITY
Mr. MUNEER KH
(2018-2020)
DECLARATION
2.1.1 Problems
The industry has been facing a number of constraints; unreliable database for availability of
raw materials, shortage of raw materials, infrastructural limitations, limited research and
development support, difficulties in technology transfer and absorption, unorganized state
of industry, inadequate incentives, problems relating to quality control, implementation of
the prevention of Food Adulteration Act, high cost of product development and promotion,
taxation policies that continue to treat this
industry as catering to the elite sections and problems relating to packing. The policy
measures, which the government has sought to initiate, are meant to remove those
constraints. The Government of India encourages the food processing industry very well.
Per capita rice consumption has declined in recent years in many of the wealthier rice-
consuming countries, such as Japan, the Republic of Korea and Thailand, because
rising incomes have enabled people to eat more varied diet.
Although rice is widely grown and consumed, less than 6% of world population (20-24
million tons) is traded annually.
6) THAILAND
1) CHINA
7) MYANMAR
2) INDIA
8) JAPAN
3) INDONESIA
9) PHILIPPINES
4) BANGLADESH
10) BREZIL
5) VIETNAM
India is one of the world’s largest producers of white rice and brown rice, accounting for
20% of all world rice production. Rice is essential to life in India. It is a part of nearly every
meal, and it is grown on a majority of rural farms. This country has the biggest area under
rice cultivation, as it is one of the principal food crops. Agriculture is the means of livelihood
of about two-thirds of the work force in the country. The demand for rice in India is
projected at 128 million tons for the year 2012 and will require a production level of 3000
kg/hectare. Some facts about rice in Indian scenario are as:
Agriculture is the main source of income for families in India. Farms cover over the half
of the land and almost three-quarters of that land is used to grow the two major grains:
rice and wheat.
India’s annual production is around 90-100 million tons.
In India rice is cultivated in both seasons – Kharif (80-85 %) and Rabi. Only in Southern
India, due to its tropical environment condition, it can be cultivated in Rabi season also.
West Bengal, Uttar Pradesh, Andhra Pradesh, Punjab, Tamil Nadu, Bihar, Orissa, Assam,
Karnataka and Haryana are the major producing states. More than 50% of total
production comes from the first four states.
Food Corporation of India purchase around 20-255 of the total rice production in the
country both under levy from the rice mills and directly in the form of paddy from the
farmers at Minimum Support Prices announced by the Govt.
More than 4000 varieties of rice are grown in India. However, government classifies rice
into two categories: common (length to breadth ratio less than 2.5) and Grade A (length to
breadth ratio more than 2.5).
India’s basmati rice and non-basmati rice exports are valued at US $800 million per annum
India is the world’s largest exporter of Basmati rice, selling about 6-7 lakh tons of the
premium rice mostly to Middle East Countries, Europe and the United States every year.
It is estimates that the rice requirement of Kerala is about 7500 tons per day whereas the
production within the state is grossly inadequate to meet the requirement. The productivity
of paddy in the state at the current level is sub optimal, meeting only
15% of the requirement, and the remaining 85% requirement is met from the neighboring
states of Tamil Nadu, Andhra Pradesh and Karnataka.
Modern rice mills are scientifically up-to-date units, with most modern plant and machinery.
Rice produced in a Modern rice mill would be of superior quality and thereby finding greater
customer acceptance. Further, the bye-product of such Mills, Rice bran could find great
demand as raw material among solvent extraction Plants. Paddy cultivation was part of the
proud culture of Kerala state. In Kerala you can see vast green paddy fields. Kuttanad is
called as rice bowl of Kerala because of rice cultivation. Kerala government has
implemented novel schemes under food security programmed for special rice production
areas like Kole, Pokkali, Kuttanad, Onattukara, Purakkad Kari, Kattampalli, Palakkad, etc.
Paddy cultivated in almost all districts.
Rice production has experienced continuous decline in area over 2 decades. Rice production
touched it’s of around 14 lakhs tons in the mid-seventies. Even at its peak level internal
production was hardly sufficient to meet 50% of states requirement. Consequent to the
enormous pressure which high value crops like coconut, banana, pineapple and rubber have
exerted area under paddy has declined from its peak coverage of 8.81 lakhs hectares in mid-
seventies to 3.05 lakhs hectares in 2003-2004. In the earlier days rice used to be cultivated
almost in all parts of Kerala in three seasons. They were Mundakan, Viruppu and Puncha.
In the present scenario it is difficult to do rice cultivation in the state due to high labour cost
and shortage of farmers who have interest in cultivation of rice. By adopting good quality
seedlings, adequate use of organic manure, integrated water and pest management Kerala
farmers can increase rice yield and thereby profit from it. Also paddy fields are being
converted into filled up lands.
Rice fields are slowly diminishing from Kerala, creating threat to food security of the State.
For conversion of paddy fields, Kerala government had made law to stop filling the paddy
fields for uses like construction and cultivation of cash crops like Rubber, Coconut tree etc.
There has been an unprecedented hike in the price of rice over Kerala for the last three years.
At present, the paddy milling capacity available
in the State is about 3000-5000 tons per day giving an output of only about 2000 tons of rice
per day, leaving a huge gap which is met by Public Distribution system (PDS) and by import
of paddy/rice from other states. As per figures from Rice Mills Owners Association, there
are about 125 rice mills operating in the state, out of which about 50% are modern
sophisticated units with Whitener and color sortex machinery and others are partially
modernized or upgraded from the traditional rice mills( by incorporating dryer systems).
The remaining units are having capacity to process only about 10 tons of paddies per week.
2.1.5 Trends in paddy cultivation
Rice is the staple food for the people of Kerala, and traditionally, the cultivation of rice
has occupied pride of place in the agrarian economy of the state. The area under paddy
cultivation increased substantially doting the first fifteen years after the state formation –
from 7,60,000 hectares in 1955-56,rice accounted for the highest share of gross cropped
area in Kerala(32 percent of the total). There was however , a steady decline in the area
under rice cultivation from the 1980s onwards- from 8,50,000 hectares in 1980-81 to
5,60,000 hectares in 1990-91, 3,20,000 hectares in 2001-02 and 2,30,000 hectares in 2007-
08. Today rice occupies only the third position among Kerala’s agricultural crops with
respect to area under cultivation, and it is far behind coconut and rubber.
Between 2007-08 and 2009 -10 the area under rice cultivation in Kerala increased by 5000
hectares and the production of rice in the State increased by 69,300 tonnes. The average
productivity of rice cultivation in Kerala rose from 2,218 kg/hectare in 2002-03 to 2,557
kg/hectare in 2009-10. These increases may be termed marginal, but, given the steady
decline in paddy cultivation in Kerala through the 1990s and 2000s, a reversal of that trend,
however small, in itself a remarkable feat.
2.2 Company Profile
Mr. K. K. Karnan started rice manufacturing business in a small way. In the beginning paddy
was boiled in large copper vessel and was dried on mats before removing the husk in milling.
Thus the rice was manufactured in traditional way in small quantities and sold locally. Later
in 1976 a rice mill with a small huller was installed and rice with better quality was
introduced in the market of Kerala, but in small quantities. That was the beginning of Mr.
K. K. Karnan’s entry into the different markets of Kerala.
In 1992 he imported computerized sortex machine and introduce it in the process line. The
sorting process helped in sorting only the quality rice thus removing all black rice. Black
rice is caused by the attack of insects to the paddy. This black rice used to cause stomach
upsets. By using the sortex machine Nirapara is able to give the best rice to customers. This
is how Nirapara silky sortex rice came to the market. Not only good looking rice but also
quality rice with all nutritious factors is given to the customers. Nirapara become a synonym
for quality rice.
In 1993 with the firm intention of modernizing the manufacturing process, a new plant with
par-boiling system was installed. This system helped in retaining all nutritious factors of
rice without losing them during the process. Thus he is able to supply customer’s quality
rice, which had all nutritious factors. The quality conscious people of Kerala encouraged
him by purchasing more and more of Nirapara. He made it his goal that he will give quality
rice to the customer.
Care is taken and many quality control measures are introduced and complied with during
the entire process from sourcing the paddy to reaching the quality rice to the customer.
Nirapara rice and rice products are now available and sold not only in Kerala but also other
states of India and exported to other foreign countries also. Nirapara rice products are
prepared by retaining the nutritious factors of rice in traditional Kerala style of preparation.
Only selected quality sorted rice which is full
of factors that give taste are used in the preparation of these rice products. These rice
products are used in the preparation of different Kerala snacks and dishes.
Mr. K.K.Karnan has his presence in the social, culture and economic fields. Mr.
K.K.Karnan is the award winner of ‘Akshaya Puraskara’ for traditional industry in 2000,
Treasure of all Kerala rice mill owners Association and member of all Rice India Exporters
Association. His wife Mrs.Ammini Karnan is looking after the manufacturing of rice
products and his son Mr.Biju Karnan who joined his father in this field after pursuing MBA
is assisting him.
The factory of KKR Mills is located in Okkal Township, near Kochi. The facility is
equipped with the latest technology in the world for every aspect of paddy-right from
cleaning, drying, and bran removal, polishing, and finally sorting. This infrastructure of
around 25 crore of rupees is one of the largest in India.
KKR mills are the only rice mill in south India to use the Z-Sortex machine capable of
optical inspection for quality control. This machine scans every grain of rice and removes
discolored, broken, and immature rice, ensuring that only rice that meets the specification
calibrated in the computer is selected for packaging. The result is beautiful rice of even size,
color and bran that is a feast for the eyes and a whole some meal. NIRAPARA- the brand
name in which KKR mills market’s rice today the largest selling brand in Kerala and has
become a household name. The KKR mill is now all set to become a name to reckon within
food. KKR mills boasts of a state of the art plant with the highest level of technology in the
world ensuring products that meet the stringent quality and hygienic standards.
The other prestigious divisions of KKR group include Vydyaa Ayurveda and herbals, Bik
Herbals & Extractions, Succor Health Care, Solace Research Pvt. Ltd, Bikaura Power
Solutions Pvt. Ltd, K.K.R Petroleum Products, Five Star Metals Pvt. Ltd, KKB Fencing
Company LLC, Dubai
About the Company
Workforce 1300
Target growth of sales 18%
Economic Objectives
Profit Maximization
Cost Minimization
Production of goods
Creating customers
Innovations
Social Objectives
Quality goods and services
Reasonable price
Provision of employment
Utilization of resources properly
Welfare of employees.
2.2.3 Values of the company
High quality products
Customer Orientation.
Good relation between management, employees and workers
Certification
ISO 22000-2005 certification
ISO 9001-2000 certification
HACCP Certification ( Hazard Analysis Critical control Point)
Mission statement
The mission of the company is to deliver high quality food products that set themselves
apart from others in taste and value.
Vision statement
The KKR Group of Companies has a great vision of becoming a leader of fast moving
consumer goods and products. Its vision is to provide total consumer satisfaction through
continuous improvement in production process and services.
2.3 PRODUCT PROFLIE
NIRAPARA rice is available in a wide range of verities suit various tastes-brown
rice, white rice, round-grained and long grained varieties. Besides theses, there are special
rice varieties for the varied traditional food all over the world. Rice is being the staple food
from breakfast to dinner and dessert. Nirapara’s range in the lives of the people especially
of south India. Nirapara rice is the only rice, which using nutria- select process, which
ensures that only the best quality rice is used. The optimum value of vitamin- B is selected
by the Z-sortex machine and then packed. Sortex machine is with 32 micro cameras for
sensing rice. The characteristic feature of Nirapara rice is its double boiling. All the activities
are controlled by a control panel program logical control system. And in Nirapara brand
there are four kinds of products which are sells mainly. They are; 1) rice products 2) rice
flours 3) spices and 4) pickles
2.3.1 RICE
The rice which has been dried and separated from the husk is subjected to neutral selection
processing and packaging by highly advanced Z3- Sortex units that employs ‘optical
inspection’ to maintain quality control on all its products. The result is that NIRAPARA’S
consumers. The verities of rice’s are follows;
PALAKKADAN MATTA
Palakkadan matta - short again (unda) is single boiled round white rice. It is bold and short.
Matta rice has many nutritional benefits over white rice that is perfect for the preparation of
idli, Dosa and is also, used for traditional Kerala food items Puttu, Appam, Idiyappam and
Pathiri etc.
PONNI RICE
Nirapara ponni rice is amongst the most favored ponni rice brand across south India. Ponni
rice is the staple rice variety of Tamil Nadu, Karnataka and Andhra Pradesh and it is a very
high yielding healthy rice variant which is generally designed for optimized cultivation.
Ponni rice is used in Kerala too. Nirapara ponni rice is a pre-boiled version of the famed
ponni; the name derived from the word denoting gold in Tamil and is almost as, famous
as matta in Kerala. It is a medium grain rice variety which is soft and expands lengthwise
when cooked.
SUREKHA RICE
Surekha rice has many nutritional benefits over the white rice. Since this rice is
comparatively thin and long to white rice, it takes less time to cook.
JEERAKASALA RICE
Jeerakasala rice, also known as wayanadan kaima, is popular traditional small aromatic
rice. Calicut biryanis are usually made with this special rice.
CHERUMANI RICE
Par boiled/ double boiled round rice which is shorter in size and white in color. Red
parboiled long grained rice; the most popular and preferred rice in Kerala and is the tastiest
among the group.
Nirapara’s wide array of traditional Kerala rice products stay true to Kerala’s unique flavor
while proving to be nothing short of a delectable feast for your taste buds. With supreme
taste and a richness that melts in your mouth. Nirapara’s scrumptious rice products have
been making daily breakfast a lingering experiences both, in taste and togetherness for
families all over Kerala. They are;
PUNCHA PUTTUPODI
Puncha puttupodi is the special type of puttupodi. Its preparation involves an intricate
process, where the rice is milled by retaining the bran surrounding the grain which is
highly nutritious and rich in fiber content.
VATTAYAPPAM PODI
Vattayappam, the steam rice cake, is a typical Kerala Christine cuisine. It is one of the
most common sweet in central Travancore households and an unavoidable ingredient
of all festival. It is a healthy evening snack best served with a cup of tea or coffee.
PATHIRI PODI
Pathiri is a traditional dish which is exclusive to the palette of the Kerala cuisine. It is thin
rice pancake made of fine ground rice. Pathiri or pathil is a tasty breakfast or dinner dish,
which tastes good with especially non-vegetarian accompaniments. It is a staple diet of the
Muslim community, primarily in north Malabar. Pathiri has already made its mark across
Kerala due its extreme light texture and melting softness. Nirapara pathiri powder is ground
to perfection, making it the perfect ingredient for mouthwatering pathiris.
CHEMBA PUTTUPODI
Wheat based traditional foods are popular in Kerala. Chemba puttupodi is made by using
different variety of rice in balanced combination. It is the balanced combination of rice
power and wheat.
IDDLI PODI
Idli is the most famous south Indian breakfast dish in any south Indian cuisine. Nirapara idli
podi is the soft idli batter which is your ideal companion in making soft, tasty idlis.
DOSA PODI
Dosa is undoubtedly the king of south Indian breakfast cuisine, which is a traditional
pancake made of rice batter, has made its mark on the taste buds across the globe. Nirapara
Dosa powder is a preferred Dosa batter for restraints and homes to its fine nature and perfect
ratio of rice to lentils. The rice as well as lentils is first processed in latest technology
machines to achieve the famed Nirapara quality, without losing its nutritional value. Then
the ingredients are processed in ideal ratio and controlled conditions, giving Nirapara Dosa
powder its unique taste and quality.
FRIED RAVA
From Kerala in south India comes Nirapara uppuma rava, a coarse version of wheat flour.
It is used to make the dish.
AVALOSE PODI
Avalose podi or avilose podi is a podi is a rice powder dish that can be used to prepare
avilose unda (a sweet dish). Avalose unda is used in Kerala as a snack.
INSTANT IDIYAPPAM
Healthy, nutritious and yummy rice idiyappam, the authentic cuisine of Kerala made in an
instant with Nirapara instant idiyappam.
PAYASAM RICE
The most favored variety of rice used for payasam/ kheer, due to the taste, aroma and quality,
payasam rice is distinct from other varieties of rice due to its distinctive reddish tint,
signature rawness and unmatched non-sticky nature dish.
2.3.3. WHEAT PRODUCTS
Wheat and wheat based products have been popular with Kerala’s as well as other rice
consuming population since time immemorial. To cater to these popular demands, Nirapara
has been bringing to the market a wide range of wheat based products.
ROASTED SEMOLINA
Rava or sooji as it is called is a purified variety of wheat middling’s is used primarily for
preparing uppma, pancakes, baby cereals, rava Dosa and sweet dishes like kesari/ ksheera,
Nirapara rava/ sooji is also famous across India for the preparation of halva.
traditional south Indian breakfast dishes made from wheat. There is certain biryani verities
also prepared from Nirapara broken wheat.
2.3.4 PICKLES
The pickle is a side dish without which an Indian meal is incomplete. Prepared in a
traditional manner using a variety of vegetables, masalas and oil to maintain international
standard in quality, taste and nutritional value, Nirapara employees the latest technological
advances in producing its line of mouthwatering pickles, which are prepared using assorted
ingredients of the highest quality, under the watchful eyes of some Kerala’s well renowned
culinary experts.
GARLIC PICKLE
Garlic pickle, a mélange of flavors marinated with garlic combined with spices, to make a
rich, complex, bold spicy pickle.
GINGER PICKLE
Nirapara ginger pickle is another south Indian pickles be a lot spicier than the north Indian
varieties of pickles. It is prepared using peeled and shredded or crushed ginger soaked in
tamarind pulp and a whole lot of traditional spices are added to it.
FISH PICKLE
“A unique flavorful and aromatic pickle”. We can make fish pickle by using sardine, butter
fish, seer fish, prophet etc. we include a non-veg item daily in our menu.
PRAWN PICKLE
True to its fishing roots and its coastal tradition of pickling seafood, Nirapara prawn pickle
delivers the goodness of Kerala spices prepared with fresh prawns are de-shelled and
deveined which are cooked in a rich mix of Indian spices and allowed to cool and soak for
a few days before it is bottled for consumption. Nirapara prawn pickle is offers ready to eat
pickle packed with the best fresh prawns and spices. It is normally consumed as an
accomplishment with rice based meals or any Indian bread.
MIXED VEGETABLE PICKLE
Pickle or chutney lay on the table during meals increases hunger as well as the food’s taste.
There are numerous types of pickles which are made in different ways. You can make a
mixed pickle comprising cauliflowers, carrots, peas, beans, turnip etc. and have it with your
meals
SHATHAVARI PICKLE
Shathavari is one among the herbal plant that must be in your garden. They can be eaten as
raw salad, boiled or steamed; stir-fried and can be stored long pickle form. Authentic spicy
pickle made from shathavari (asparagus) with aromatic spices.
BEEF PICKLE
This is one of the sought after pickle from Nirapara. The traditional Syrian Christian variety
favorite made from beef/ stew meet with aromatic spices.
TENDER MANGO IN BRINE
Simple and tasteful recipe that is extremely popular in south India. Malayalees one favorite
comfort food when served with kanji.
KANDHARI IN BRINE
Simple and tasteful recipe that is extremely popular in south India. Malayalees favorite
comfort food when served with kanji.
CLAM PICKLE
Authentic home style pickle made from clam with aromatic spices. Enjoy special quality of
rusted pickle clam that goes well with most rice dishes.
PEPPER IN BRINE
Simple and tasteful recipe that is extremely popular in south India. Malayalees favorite
comfort food when served with kanji.
2.3.5 SPICES
To health discerning housewives world over prepare service that are tasty and nutritious
while in essence remaining truly “keraleyan” KKR food products in 2002, launched the
pioneering Nirapara curry masala brand. In order to ensure cent percent purity, Nirapara
curry masala unit is the only food processing unit in Indian where in the products are
subjected to a four stage process of steam sterilization to render them completely germ free.
IYENGAR SAMBAR POWDER
“Sit back and savior the taste of homemade iyengar sambar”. All with Nirapara food
signature recipe, made the authentic Hindu Brahmins way. Garnish it with finally chopped
coriander leaves and enjoy it with rice, Dosa or idli.
quick breakfast .
CHILLI POWDER
Chili powder is the dried pulverized shoot of one or more varieties of chili. It’s used as spice
to add pungency flavor to various dishes. Chili powder blenders are popular in many types
of cuisine.
CHICKEN MASALA
Chicken curry is a common delicacy in south-Asia and in the Caribbean, where it is usually
referred to as curry chicken. A typical south- Asian curry consist of chicken stewed in an
onion and tomato based souse, flavored with ginger, garlic, chilies and variety spices
which includes turmeric, cumin, coriander, cinnamon, cardamom and so on. Outside
south-Asia, chicken curry is often made with a pre made spice mixture known as curry
powder.
MEAT MASALA
Meat masala is spices mix used in Kerala cuisine. It is typically used to marinate various
types of meat which can either be rubbed on to pieces of meat as a dry powder mix or
combined with oil to make a paste that easily cotes the meat.
MUTTON MASALA
A perfect blend for an aromatic spicy mouthwatering mutton dish will make a perfect
FISH MASALA
The blend use of pure spices in accurate measurements that it brings out the best in one
your favorite fish and make it ready to eat in no time
BIRIYANI MASALA
Its blend of whole spices lightly roasted and powdered. It’s used specially for biryanis.
The masala powder adds not only a flavor but also a faint aroma that is required in a perfect
biryani.
CHUKKU KAPPI
Chakku kappi is the herbal medicinal decoction using pungent spices like dry ginger pepper
com cumin and an aromatic herb like tulasi/holy basil with a touch of jaggery and flavored
by coffee or tea.
ORGANISATIONAL STRUCTURE
3.1 Organization structure
Chairman
Vice Chairman
CEO
Cost A M Flour
Accountant Chemist
A.M Food
Lab
Assistant
Vehicle
Drivers Helper
Manager
Authority
General Manager and other managerial personnel have authority in the concern. They can
take decisions in consultation with their subordinates. But they cannot take decisions,
which involve a financial commitment of higher amount with the consent of the chairman
or vice chairman.
Responsibility
Everyone in the organization has his own personality. The duties and responsibilities are
given to each of the employees upon his appoint. Managers head the departments. They
are responsible for the working of their respective departments. They report to the general
manager.
Department details
A department is a distinct section of the business establishment concerned with a
particular group of business activities. Department comprises a framework for an
organization and enable it to expand indefinitely. Departmentation aims at
Specialization of activities for efficient performance.
Simplifying task of management within a workable span.
Maintaining co-ordination and control of the various activities.
CHAPTER :4
FUNCTIONAL DEPARTMENTS
4.1 Purchase Department
Purchase Manager
Helpers Helpers
This department plays a very important role in the organization because purchasing has its
effect on every vital factor concerning the manufacturing, quality, cost, efficiency and
prompt delivery of goods to the customers. Its function is to procure materials ,supplies,
services, machine and tools at the most favorable terms consistent with consistent with
manufacturing the desired standard quality. The purchase system is centralized in Nirapara.
Centralized purchase department means that all the purchase functions are routed through
one department. This means all purchases should be made by the purchase department to
avoid duplication, overlapping and non-uniform procurements.
Purchasing will be;
Seasonal purchase – It includes the purchase of paddy, chilly, turmeric etc. Purchasing will
be mainly from open markets, supplyco, and also through agents. Paddy is mainly purchased
from Palakkad, Alappuzha, Tamil Nadu, Karnataka etc.
Daily purchase – It includes machine parts, office materials and other materials for the day
to day needs.
The purchase department in KKR Mills is mainly divided into 5 sections. Each section has
a purchase manager. The sections are:
What to purchase?
When to purchase?
Where to purchase?
How much to purchase?
4.1.3.1 Procedures
3. Purchasing Order
After choosing the supplier, the purchase department prepares a purchase order for the supply
of stores. The order is the written authorization to the supplier to supply the particular material
or materials. If five copies are prepared, the possible use may be as follows:
KKR Mills adopt certain internal checks regarding purchase. They are:
Checks whether purchase requisition showing correct quantity, quality, and time by
which the good are required.
Accept best suitable tenders.
Stores department should prepare “goods received note “
Invoice clerk check the details of invoice
Examine the debit notes and see that they are properly entered in purchase return book.
All manufacturing concerns appoint a person known as the store keeper. Chief store
superintendent is given the charge of the stores department and is also responsible for stores
control.
PRODUCTION MANAGER
Labors
Production in Charge
Production department is deals with the process of producing Product. It means converting
input into output. Materials are a very important factor of the production process. It includes
physical commodities used to manufacture the final end product. Production is
manufacturing. Manufacturing was referring to the process of producing tangible goods
whereas production includes creation of both tangible as well as intangible service.
1. Production Manager
o Plan production of products as per the target allotted for the month.
o Check and verify the process sheet
- Parboiling and drying process sheet
- Milling process sheet
- Sortex section process sheet
- Packing register
- Mechanical maintenance register
- Electrical maintenance register
- Goods received register
- Final product stock register
o Inform the manager regarding the stock of by- product and other item.
o Ensure good control over the labours.
o Prepare weekly wage list and ensure disbursement of weekly wage by the cashier.
o Prepare a monthly salary statement and handover to the account department.
o Maintain the attendance register for production staff.
o Ensure leave sanction of all employees and one copy of leave application is forwarded to
HR department.
o Ensure that the pollution control norms are properly informed.
o Ensure timely water disposal from the mill.
o Conduct monthly meeting.
2. Paddy Inspector
3. Mechanic head
o Ensure maintenance of all mechanical equipment.
o Maintain a register of schedule of maintenance.
o Maintain a register of repairs.
o Maintain all spares in a locker or spares room.
4. Milling Supervisor
5. Electrician
6. Dispatch Supervisor
7. Parboiling Operator
8. Milling Operator
9. Sortex Operator
The manufacture of rice from paddy is done in three stages that is the parboiling, drying and
milling. From the paddy godown the paddy is transferred to raw paddy bin and the paddy
was separated as long and short grain. It was pre-cleaned using MTRA machine and
destonner where the impurities and immature paddy were removed.
PARBOILING
The cleaned paddy is taken to the paddy storage tanks through an elevator, where it is
soaked in water to remove the immature paddy completely. The rice will be soaked for 6
hours. The soaked paddy is then taken to the parboiling tanks through a metal chute. The
paddy is boiled to the required level in the parboiling tank using the steam produced by the
boiler machine.
DRYING
For drying the paddy will be shifted to the drying machine using a conveyor system. A
thermic fluid is used to pass hot air through the paddy. The water content in the hot air will
be removed using a heat exchanger machine. To keep the moisture level of paddy within
the limits the temperature should be maintained.
MILLING
In the milling section, the dry paddy is taken to the precleaner where it is cleaned once again.
Using a huller machine, the husk will be removed first. The husk will be collected and used
as fuel for the different machines. Then it goes to a paddy separator which will separate the
unshelled paddy and the rice. The unshelled paddy will go back to the huller machine. The
rice will then go through the thickness grade which separates paddy which have 3mm
thickness and which won’t have. Because it is the standard thickness for the rice, which is
manufactured from the rice.
The rice will be polished by passing through 3 machines. After the polishing the bran of the
rice will be completely removed. The bran will be collected and used to make other by
products. After polishing, the rice will go the destonner machine and vibrator machine,
where the impurities and broken rice are completely removed.
4.2.6. STRUCTURE OF PRODUCTION PROCESS
1ST PHASE
CLEANED
RAW PADDY DESTONER
PADDY
CLEANER
PARBOILING TANK
DRYING PLANT
BRAN
REMOVAL
POLISHING
Z-SORTEX PACKAGING
DESTONER
DISPATCHING
MTRA
MACHINE
Chart No.4.2.3 Structure of Production
process
The specialty of the NIRAPARA rice brand is, it is silky sortex rice. So to achieve this, the
rice will be passing through the polishing machine silky and the sortex machine. The silky
machine removes the oil content of the rice where the sortex machine is used to sort the rice
from the black rice. The sortex machine is a hi-tech machine has the capacity to sort 3 and
half tons of rice in an hour which will remove the black rice completely. The final product
will be superior in quality and it will dispatch after the packing.
The KKR Group of companies markets a number of diversified products in the competitive
market. Marketing department works as a separate department with in the business
enterprise and deals with all the sales and market related activities.
The word marketing is a common word in every day’s life. It has a major role in a
manufacturing organization. Marketing is the distinguishing unique function of the
business. The main objectives of marketing goods and services are to satisfy the customers.
This department is considered as the assets of the company. Marketing managers are often
responsible for influencing the level, timing and composition of customers demand in a
manner that will achieve the company objectives.
Marketing Zones
South zone Central zone North zone
Idukki Ernakulam Kannur
Kottayam Alappuzha Palakkad
Trivandrum Thrissur
Pathanamthitta Kasargod
Kollam Calicut
Malabar
Table No. 4.3.1
4.3.1 STRUCTURE OF MARKETING DEPARTMENT
GENERAL MANAGER
(MARKETING & SALES)
BUSINESS HEAD
(INTER STATE)
TECHNICAL
MARKETING
MANAGER
SALES SALES
SALES REPRESENTATIVE REPRESENTATIVES
REPRESENTATIVES
Marketing Manager
Sales Executives
Collect orders from different shops
Fix the driver’s route for sale
Identify complaints of consumers
Give information about consumers
Inform about market which has more sale
Market Research Analyst
4.3.4 Distributors
The KKR Group of companies has a large of distributors in Kerala, major cities in India
and abroad, U.A.E, Muscat, Bahrain, Oman, Canada, Qatar, Australia, etc. The company
selects the distributors in those places where Keralites are located. Considering the
increasing demand they have plants to increase the number of distributors. The
communication between the general manager, area sales manager, sales representatives and
distributors is through telephones and internet.
Distribution channels
The varied products are supplied to all the retail outlets all over Kerala. Direct marketing
system is followed to move the products from the manufacturer to retailer and then to
customer. The company is also having a small outlet for the sales of the products.
The main dealers include the supermarkets, wholesale institutional buyers, grocery shops,
etc... The length of the channel is one level channel which contains some selling
intermediaries as retailers. This is used by manufactures for marketing fashion merchandise.
Advertising is the process through which the consumers are getting information about the
product. It increases the sales and helps in creating a brand name and consumer loyalty. The
advertisement efforts can be channelized as follows:
Wall paintings
Boarding and boards
TV\Radio\Newspaper
Side panels on KSRTC Buses
The TV commercial was the main factor for the wide acceptance of the brand.
4.3.6 Pricing
o Competitors price
o Cost of production
o Buying pattern of the consumers
o Distribution channel
Now the price of Nirapara ranges from 40-50 Rs/kg and available in 2-50 kg quantities.
Some products of the company get a high profit while others get a less amount of profit
only.
4.4 Human Resource Department
4.4.1 Structure of HR Department
HRD MANAGER
OPERATION PERSONNEL
MANAGER MANAGER
ASSISTANT
OFFICER RECEPTIONISTS
EXECUTIVES
HELPERS
This department involves specialized knowledge and approaches that allow more
emphasis on human resources and its proper selection, training and development. Personnel
management is the management of people employed. It is concerned with human resource
management in the organization. The main function of this department is to make optimum
utilization of human resources and also to provide proper satisfaction to employees.
The development of the organization can be achieved through the development of the
people of the organization. So we can say that workers are the backbones of the
organization. The impressive level of productivity is a hallmark of KKR Group of
companies and today the company have highly committed and disciplined workforce which
leads a high degree of productivity with impressive levels of quality. The company gives
importance for employee welfare and individual development of them. The organization
promotes the concept of participative management, especially in quality circle, employ
suggestion schemes etc.
4.4.2.6 Bonus
KKR group provide bonus to its employees to motivate them. The profit of the concern
was increasing every year due to the devoted hard work of employees.
Leave
o Casual leave
o Earned leave
Permanent employees get 15 days casual in a year and trainee get 12 days casual leave.
According to the industrial law every employees has an earned leave of one for 20 days
work. i.e.; 12 days in a year.
Office time
KKR group adopt facility for the entry and exit of the employees. The 24 hours working
factory provides shift facility to the workers.
Time of working in : 9.00 am to 5.00 pm
: 5.00 pm to 1.00 am
: 1.00 am to 9.00 am
A committee consist of seven members, representing every department evaluate the safety
measures for the welfare of the workers. They discuss the matter once in a month and take
necessary steps for the maintenance and implementation of safety measures.
Promotion
For promotion, length of service or experience with not be taken into consideration, it
follows a performance based promotion system.
4.4.2.10 Welfare
Welfare includes anything that is done for the comfort and improvement of employees
and is provided over and above the wages. Welfare helps in keeping the morale and
motivation of the employees high so as to retain the employees for longer duration. The
welfare measures may not be in monetary terms only but in any kind of form.
Accident insurance
Lodging facility
Transportation facility
Canteen
Dispensary
Welfare funds
Wage records includes Attendance record (time recording clock, use of tokens,
attendance card), piece work records, over time records, pass-out records.
The procedure of preparing the wage sheet should be clearly established to minimize the
chances of irregularities in wage payment.
Wages-salary Administration
Salary of the office staff consists of basic pay and HRA. Salary increment is made on
performance basis. For marketing staff, a certain percentage of the sale turnover is given
as commission.
FINANCE MANAGER
ASSISTANT ASSISTANT
ACCOUNTANT MANAGER CASHIER
CHIEF
ACCOUNTANT
The operational efficiency of the concern as a whole and of its various parts of
departments.
The financial stability of a business concern.
The present & future earning capacity or profitability of a concern.
The short term and long term solvency of the benefits of the debentures holder and trade
creditors.
Long term liquidity of its funds.
By producing an accurate portrayal of the potential of the profit and cost of each title, the
finance department aids all departments in making the best financial decisions. The
department is charged with the following task;
The finance manager, who is the head of the department, provides various financial
information for taking decisions. All other employees concerned are responsible to him. He
is entrusted with the duty to the insurance and other funds generating formalities. Working
capital management is another main function of the department.
• Obtaining finance
•Financial accounting
• Internal audit
• Cash management
• Taxation
• Management of accounting and control
• Payment collection of all departments
• Preparation of financial report
• Expense analysis
• Determining the source of funds
• Funds management
• Effective use of resources
• Controlling of resources
• Banking relationship
• Evaluation of group finance
4.5.5 Responsibilities of key personnel
4.5.6.1 Duties
To handle the income and expenditure of the entire organization. And
overlooking the final accounts.
Responsibility for maintenance of all vouchers, unit wise to send cheques on
daily base to bank. Another prominent staff is Cost accountant. He plays a vital
role in this department.
To calculate the expenditure incurred by sales representatives and to identify
thrust areas, if any.
To check cash credit bills of the day corresponding to cash receipts of each party.
For all partial payments of cash credit bills, debit note to be prepared.
To Proper budgeting for all activities of the organization.
Preparation of balance sheet of all units’ monthly and comparative study of
accounts and to assist in the finalization of accounts.
Provide a correct analysis of cost both by process or operations and by different elements
of cost.
Ascertain the profitability of each product and advice the management regarding how
profit can be maximized.
Guide management in the formulation and implementation of incentives, bonus plan based
on productivity and cost savings.
Organize the internal audit system to ensure effective working of different department.
Organize the cost reduction program with the help of different department managers.
Helps in supervising; the working of punching card accounting or data processing through
computers.
Responsibilities of cashier
R&D MANAGER
In KKR group of company’s research is mainly conducted in the field of production. This
department consists of lab assistant, chemist and microbiologist it leads with development
of a new product and quality inspection etc. the R@D department of KKR group is situated
at Chelamattom unit.
NEW TECHNOLOGY
The KKR group is all set to enter the food processing industry on large scale bringing in
the world latest technology and machines. In every new are of achieving attention to
purring and hygiene that meets the highest world requirements is the focus of the group.
And they also introduced mobile apps for better access.
NEW PRODUCT
The KKR group is looking at venture in food processing and presenting with a large scale
investment on a food technology park. The group has plans to manufacture an
international product range like past presents source squashes, fruits based foods, pickles,
juices, coconut based food etc.
NEW MARKET
Today Nirapara group has entered the Middle East markets and Far East America and
Europe. The day is not for because the KKR group makes food in the international
markets and with the presence and commitment of the group it needs that will be true
before long.
The main competitions of KKR groups are:
Eastern
Periyar
Double horse
Kitchen treasures
Pavizham
Gayathri (only in rice)
Marias
Saras
Melam
Taste buds (in foreign market)
Priyam masala
Brahmins
Ann’s curry powder
Achi masala (outside Kerala)
Sakthi masala (outside Kerala)
4.7 Quality control Department
4.7.1 Structure of Quality Control department
QUALITY
CONTROLLER
ASSISTANTS
Improve quality is one of the important way to maintain a competitive position on today’s
markets. When quality is emphasized and subsequently improved, waste is decreased and
operation cost is reduced. By maintaining quality the customer acceptance of the brand can
be increased.
K.K.R Mills is the only rice mill in south India to use the z-sortex machine capable of optical
inspection for quality control. This machine scans every gain of rice and removes
discolored, broken and immature rice, ensuring that only that meets that specification
calibrated in the computer is selected for packaging.
The pickle division of K.K.R Group is using sensitive metal detectors before the sealing is
done. This also ensures the quality of products. Quality control is very important for the
products which are exporting.
The KKR Group of company is aware of their commitment to the society. A healthy
environment is essential for substantial development. The company’s procedures are eco-
friendly. The quality section is headed by a quality controller. He has assistant to assist him
in quality checking.
Quality objectives
ISO CERTIFICATE
ISO 22000-2005 specifies requirements for a food safety management system where an
organization in the food chain needs to demonstrate is ability to control food safety hazards
in order to ensure that food is safe at the time of human consumption.it is applicable to all
organizations, regardless of size, which are involved in any aspect of the food chain and
want to implement systems that consistently provide safe products. The means of meeting
any requirements of ISO 22000-2005 can be accomplished through the use of internal/
external resources.
Quality sells, sustains and quality assurance is what customer look forward from their supply
globally. KKR group is one of the companies, which recognized this business technique at
the early. Products facilities and service utilizing the expertise of independent assess of
worldwide repute. According KKR group has ISO 9001-2000 quality management system.
HACCP CERTIFICATION
Hazards Analysis and Critical Control Point (HACCP) is a process control system designed
to identify and prevent microbial and other hazards in food production. It includes designed
to prevent problems they occurred and to correct deviation as soon as they are detected.
Such preventive control system with documentation and verification are widely recognized
by scientific authorities and international organizations at the most effective approach
available for producing safe food. HACCP involves a system approach to identification of
hazard, assessment of chances of occurrence of hazards during each phase, raw material
procurement, manufacturing, and distribution, usage of food products and in defining the
measures for hazard control.
EXPORT
MANAGER
EXPORT
ASSISTANTS
LIAISON EXECUTIVES
OFFICER
KKR Group is mainly involves in the manufacture of quality Rice and Rice products, spices,
spices product, etc. The products are sold under the brand name “Nirapara”. The capacity
of the plants of the KKR Group is 225 million tons.
Nirapara products are exported to UAE, Muscat, Bahrain, Oman, Qatar, France, Australia,
Singapore etc. and 20 % of the turnover is exported to foreign countries. The company gives
the export authority to only to Authorized dealers. There are also local merchant exporters
in different countries like Malaysia, South Africa, etc... The local merchant exporter takes
the good according to their requirement only.
For exporting the order is given by the authorized dealer. The exporter gives H-form (Halal
Form) as the proof of export. This order is refrained on the basis of container and inform to
the dealer. If the dealer is satisfied with the conditions, then gives the conformed purchase
order. Shipment takes place within 10 days. C&F (clearing and
forwarding) agents help for shipment. And the shipment is received in any of the following
methods
The most common type of payment is bill collection method. Government gives some
incentives to export company because they are bringing income from abroad to our country.
The export company should submit returns to Government (APEDA – Agriculture
Processed Food Exporters Development Authority). For exporting spices, the export
company should submit returns to spices board.
a) Export manager
b) Export Assistant
There are 2 export assistants. The duty of export assistant is to assist the export manager in
all export activities.
4.9 Vehicles Department
Vehicle department deals with the transportation of raw material from various places to
factory go down and finished goods from factory to various markets. There are 140 vehicles
in the company.
Vehicles Manager
Helpers
4.9.2 Functions
ANALYSIS
5. SWOT ANALYSIS
5.1 Strengths
High competition
Less market share (43.5%)
Raw materials are imported from the states like Tamil Nadu, Andhra Pradesh, and
Karnataka etc... So transportation cost is very high
Absence of long term policy for the sale
5.3 Opportunities
5.4 Threats
Tough competition in the market
6.1.2 Suggestions
The intention behind doing this product was to get better idea about the organization, its
different departments, responsibilities of key personnel and its competitive performance
with respect to specific operational parameters
K.K.R MILLS is a leading manufacturer for the quality assured branded rice “NIRAPARA”
marketed in Kerala state and abroad. This company is at it’s strive towards excellence. It
has happened due to the combined efforts of its management and the dedicated work force.
The activities of the plant office and all other departments are functioning at the impressive
standards for achieving the organizational objectives. The commitment and efficiency of the
employee helped K.K.R MILLS in capturing highly competitive market.
Increasing the frequency of advertisement on mass media will improve the product
awareness among the public. Strict quality control with the help of modern equipment’s will
enable the company to enter the international market. Sales turnover can be enhanced with
the help of providing more commission to retailers and damage allowances, credit facility
etc. to distributors. The main positive aspect of the Company is that it could maintain a
better relationship between the management and employees. The company does not have
any trade union for the employees and hence no labour problems. Hence we can conclude
that the K.K.R MILLS will be able to reach greater heights.
BIBLIOGRAPHY
BOOKS
Websites
www.nirapara.com
http://www.ibef.org/industry/foodindustry.aspx
http://www.keralaexporters.com/categories/food/index.html