Summer Training Project

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A

PROJECT REPORT
ON
"PRODUCTION OF BISCUITS FROM SHORT DOUGH"

Submitted To
Mrs. Nimisha agarwal
project co-ordinator
Submitted By
Mr. Arpit Nagar
BBA ( V )
Roll No. 83736
IMTK, College of Management & Higher Studies
(Affiliated to Kumaun University)
Kashipur, Udham Singh Nagar
(UTTARAKHAND) Page # 01
Arpit's
ACKNOWLEDGEMENT
Preparing a research report is not a single man's efforts. It enrich with
the joint efforts of those people who share their valuable experience
and knowledge.

I readily acknowledge my indebtness to my parents whose support,


dedication and honest efforts have given me an immense help in doing
this project

It gives me immense pleasure to express my deep sense of gratitude


and appreciation to my external guide Mr. Anil Anand (Production
Manager, Britannia Industries Ltd.) for his constant encouragement
and valuable suggestions which provided me back bone support in
completing this project.

I take the opportunity to thank Mr. Deepak Dhariyal (Internal Guide)


for motivating, encouraging and supporting at every step and sparing
his valuable time for me.

Above all I praise "GOD" the most beneficial, the most merciful that I
have been able to complete my training project successfully.

ARPIT NAGAR
BBA (2008-11)

Arpit's Page # 02
PREFACE
It gives an immense pleasure to present on the topic of "Production
of Biscuits From Short Dough". By the time, I completed this
project I understood how important it was for a BBA student to do
summer training in between the BBA program.

I have selected this topic because I was very keen to know about
the know how of production system. A distinct feature about this
project is that it provides a penetrating and comprehensive analysis
of all the aspects of production concept and how it defers from
bookish knowledge in a simple and lucid style.

A project is involving a lot of extensive study and research, it also


gave me a great deal of exposure to the production department of
an industry. I hope this project would prove useful to its readers if
it deserves.

Arpit's Page # 03
STUDENT'S DECLARATION
I Arpit Nagar student of BBA V sem. declare that this project
report "PRODUCTION OF BISCUITS FROM SHORT
DOUGH" is written and submitted by me under the guidance of
Mr. Anil Anand (Production Manager, Britannia Industries
Ltd.,Pantnagar) is my original work. The entire analysis and
conclusion of this report are based on the information which is
collected by me during the summer training period.

The empirical findings in the report are based on the data


collected by myself while preparing this project. I have not copied
anything from any source (other than provided by the industry
officials and website) or any other project submitted for similar
purpose.

ARPIT NAGAR
BBA (2008-11)

Arpit's

Page # 04
CONTENT SHEET

S. No Name of Topic Page No.


1. Title Page 1

2. Acknowledgment 2

3. Preface 3

4. Student's Declaration 4

5. Content Sheet 5

6. Chapter - 1 6-51
1.1 Introduction about the project 6
1.2 Period Of Study 7
1.3 Company Overview and its Code of
Conduct 8-23
1.4 Various Products of Britannia Industries
Ltd. 24-51

7. Chapter-2 52-81
2.1 History of Biscuits 52-54
2.2 Production 55-72
2.3 Mixing 73-74
2.4 Forming 75-76
2.5 Baking 77-78
2.6 Cooling 79
2.7 Packaging 80-81

8. Questionnaire (Internal & External) & Findings 82-92

9. Bibliography 93

10. Copy of the certificate provided by the 94


"Britannia Industries Ltd."

Arpit's Page # 05
Introduction
As a part of the curriculum of my BBA V semester, I
undergo a project in Britannia Industries Ltd. There I was
assigned the project title "Production Of Biscuits From
Short Dough". My topic is concerned with the production
system of Britannia Industries through which we can check
the various aspects of the production system like the
procedure, quality measures taken by the company, etc.

This project work provides me an ample opportunity to


judge the company's productivity condition and
performance of the workers. Through productivity we can
evaluate the company's performance in the comparison of
other companies accomplishing the same task.

Arpit's Page # 06
PeriodOf The Study
The period of the study consists of two months from 1st
July 2010 to 31st August 2010 in a reputed industrial
organization, which is one of the major industries in
FMCG sector at Rudrapur-Pantnagar Zone.

Address of the company:

BRITANNIA INDUSTRIES LIMITED


PLOT N0.1, SECTOR NO.1,
INTEGRATED INDUSTRIAL ESTATE
PANTNAGAR, RUDRAPUR-263153
Distt.: UDHAM SINGH NAGAR
UTTARAKHAND

WEBSITE:- www.britannia.co.in

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Overveiw of the Company
The story of one of India's favorite brands reads
almost like a fairy tale. Once upon a time, in 1892 to be
precise, a biscuit company was started in a nondescript
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 in 1983, it crossed the Rs. 100 crore
revenue mark.

On the operations front, the company was making equally


dynamic strides. In 1992, it celebrated its Platinum Jubilee.
In 1997, the company unveiled its new corporate identity
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"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
was voted India's most successful promotional activity of
the year 2001 while the delicious Britannia 50-50 Maska-
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 minuscule initial investment has
grown by leaps and bounds to crore of rupees in wealth for
Britannia's shareholders. The company's offerings are
spread across the spectrum with products ranging from the
healthy and economical Tiger biscuits to the more
lifestyle-oriented Milkman Cheese. Having succeeded in
garnering the trust of almost one-third of India's one billion
population and a strong management at the helm means
Britannia will continue to dream big on its path of
innovation and quality. And millions of consumers will
savor the results, happily ever after.

The Company's head office and registered office and work


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places are located at the below mentioned address:

Registered & Head Office

Britannia Industries Limited


5/1A, Hungerford Street
Kolkata-700017

Work Places

(a) Britannia Industries Limited


33, Industrial Area
Lawrance Road,
Delhi-110035

(b) Britannia Industries Limited


Plot No.-1, Sector No.-1
Integrated Industrial Estate
Pantnagar, Rudrapur-263153

(c) Britannia Industries Limited


15, Taratola Road,
Kolkata-700088

(d) Britannia Industries Limited


MTH Road, Padi
Chennai-600050

(e) Britannia Industries Limited


Ready Road(East), Mazagaon.
Mumbai-400010

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BOARD OF DIRECTORS

Name Designation

Mr. Nusli Neville Wadia Chairman

Ms. Vinita Bali Managing Director

Mr. A.K.Hirjee Director

Dr. Ajai Puri Director

Mr. Avijit Deb Director

Mr. Jeh N Wadia Director

Mr. Keki Dadiseth Director

Mr. Nasser Munjee Director

Mr. Ness Nusli Wadia Director

Mr. Nimesh N Kampani Director

Mr. Pratap Khanna Director

Mr. S.S.Kelkar Director

Dr. Vijay L. Kelkar Director

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Management Team

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Gautam Banarjee General Manager(Materials)

A. K. Gupta General Manager - Accounts & Planning

R K Agrawal Supply Chain Director for New Business


Development

R S Subramaniam General Manager - Manufacturing,


Engineering and Projects

Anuradha Narasimhan Category Director - Health & Wellness

Shalini Degan Category Director - Delight & Lifestyle

T S Venketram General Manager - Manufacturing


Development

Balaji Reddipalli Head Replenishment

R. Anand Business Operations Director

Jehanagir Tankariwala General Manager - Human Resources

Vinod Menon Head of BNZF

Shridhar Panshikar National Sales Manager

P. Govindan Company Secretary & Head of Legal

Dr. K.N. Shashikanth Corporate Quality Assurance Manager

V V Padnabham Corporate Manager -Information Systems

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Milestones for the Company

1892 The Genesis - Britannia established with an


investment of Rs. 295 in Kolkata

1910 Advent of electricity sees operations mechanized

1921 Imported machinery introduced; Britannia becomes


the first company East of the Suez to use gas ovens

1939 - 44 Sales rise exponentially to Rs.16,27,202in 1939

During 1944 sales ramp up by more than eight


times to reach Rs.1.36 crore

1975 Britannia Biscuit Company takes over biscuit


distribution from Parry's

1978 Public issue - Indian shareholding crosses 60%

1979 Re-christened Britannia Industries Ltd. (BIL)

1983 Sales cross Rs.100 crore

1989 The Executive Office relocated to Bangalore

1992 BIL celebrates its Platinum Jubilee

1993 Wadia Group acquires stake in ABIL, UK and


becomes an equal partner with Groupe Danone in
BIL

1994 Volumes cross 1,00,000 tons of biscuits

1997 Re-birth - new corporate identity 'Eat Healthy,


Think Better' leads to new mission: 'Make every

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third Indian a Britannia consumer'

BIL enters the dairy products market

1999 "Britannia Khao World Cup Jao" - a major success!


Profit up by 37%

2000 Forbes Global Ranking - Britannia among Top 300


small companies

2001 BIL ranked one of India's biggest brands

No.1 food brand of the country

Britannia Lagaan Match: India's most successful


promotional activity of the year

Maska Chaska: India's most successful FMCG


launch

2002 BIL launches joint venture with Fonterra, the


world's second largest dairy company

Britannia New Zealand Foods Pvt. Ltd. Is born

Rated as 'One amongst the Top 200 Small


Companies of the World' by Forbes Global

Economic Times ranks BIL India's 2nd Most


Trusted Brand

Pure Magic -Winner of the Worldstar, Asiastar and


Indiastar award for packaging

2003 'Treat Duet'- most successful launch of the year


Britannia Khao World Cup Jao rocks the consumer
lives yet again

2004 Britannia accorded the status of being a


'Superbrand'

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Volumes cross 3,00,000 tons of biscuits

Good Day adds a new variant - Choconut - in its


range

2005 Re-birth of Tiger - 'Swasth Khao, Tiger Ban Jao'


becomes the popular chant!

Britannia launched 'Greetings' range of premium


assorted gift packs

The new plant in Uttaranchal, commissioned ahead


of schedule.

The launch of yet another exciting snacking option


Britannia 50-50 Pepper Chakkar

2006 Britannia re-launched NutriChoice Hi-Fibre


Digestive biscuits in an international large sized
biscuit pack.

Britannia acquires 51% stake in Bangalore-based


bakery foods retailer Daily Bread.

2007 Britannia industries formed a joint venture with the


Khimji Ramdas Group and acquired a 70 percent
beneficial stake in the Dubai-based Strategic Foods
International Co. LLC and 65.4% in the Oman-
based Al Sallan Food Industries Co. SAOG.
Britannia NutriChoice SugarOut range introduced -
1st of its kind of biscuits to be be launched i India
with "No Added Sugar" (Variants - Chocolate
Cream, Orange Cream, and Litetime)

2008 Britannia NutriChoice 5 Grain biscuits launched -


Biscuits with the goodness of 5 health Cereals, and
sweetened with Natural honey. Britannia
Nutrichoice promised consumers "Bhook Bhagao,
Kuch Healthy Khao"

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Britannia launched Iron fortified 'Tiger Banana'
biscuits, 'Good Day Classic Cookies', Low Fat Dahi
and renovated 'MarieGold'.

2009 Britannia NutriChoice Nature Spice Crackers


launched - Your favorite Cream Crackers, now
made even more exciting with the addition of
"Sabut" Ajwain and Jeera spices.

Britannia takes full control of Daily Bread.

Britannia-Fonterra joint venture dairy business


restructured. Britannia acquires entire stake of
Fonterra BNZF name changed to Britannia Dairy
Pvt. Ltd.

Recognizing the changing global trends & health


benefits of removing transfats, Britannia is the first
Bakery brand in India to remove transfats from its
products.

Wadia Group acquired stake holdings from Group


Danone and becomes the single largest shareholder
in BIL.
2010 Britannia NutriChoice launches a New Year pack -
the Health Starter Kit. Created for everyone who
makes New Year resolutions and doesnt follow
through. The Health Starter Kit contains 1 pack
each of NutriChoice Hi-FiberDigestive,NutriChoice
5 Grain, NutriChoice Nature Spice Cracker bundled
together with a Fit Sip Sipper and a fitness chart.
All this only for Rs 100.

Arpit's Page # 17
Code Of Conduct of The Company
(as provided to the employees)
The reputation that Britannia has built over the years for high
ethical standards is one of our greatest business assets. To share the
responsibility to preserve and enhance this asset, the company has
documented the Code of Business Conduct (COBC) for its
employees.

The COBC outlines the principles, policies and laws that govern
the activities of the company, and to which employees of Britannia
and others who work with, or represent Britannia directly or
indirectly, must adhere. The Code is distributed to all employees
and directors and others associated with the business of the
Company, and offers guidance for professional conduct under six
main headings, which include the following key points:

1. Responsibilities of Employees of Britannia

Maintaining ethical standards, including appropriate


accounting controls;
Identify, surface and resolve ethical issues with great speed;
Corporate assets (physical and intellectual) must not be used
for personal benefit;
Exercise good judgment and standards of good taste when
creating company records, including e-mail;
Maintain company records accurately and retain them in
accordance with law.

2. Workplace Responsibilities

Being committed to fair employment practices;


Being committed to a workplace free from drugs and any
kind of harassment or intimidation of employees;
Being committed to the safety of our employees;
Being committed to discipline at workplace;
Compliance with appropriate laws and internal regulations.

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3. Representing Britannia to Customers and Other External
Constituencies

Treating customers, suppliers and competitors fairly;


Maintaining high standards of quality;
Speeches, media interviews, and other public appearances in
connection with Britannia must first be approved internally;
Preparing accounts accurately and maintaining records;
Ensuring not to use unfair and misleading statements when
marketing Britannia products and services;
Accepting and giving gifts is not permitted, except as
governed by the policy laid down herein.

4. Privacy / Confidentiality

Protect proprietary and confidential information at all times


in accordance with applicable law;
Keep customer information secure at all times, as a sacred
trust given to the company by our customers;
Keep employees' information confidential.

5. Investments and Outside Activities

Trading in the securities of Britannia or any other company


while in possession of "inside" information is illegal;
Avoiding real or perceived conflicts of interest in areas
including investments or outside business activities, among others.

6. Corporate Social Responsibility

Catering to the national interest


Committed to be a good corporate citizen
The company prohibits any payment of bribes.

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ADMINISTRATION OF THE CODE

DISTRIBUTION

All the directors of the company and employees will receive


a copy of this Code at the time they join the company and will
receive periodic updates. Also, any agent, consultant, government
official or government employee who is retained by the company
should receive this Code and understand the obligations under it.

APPROVALS

The appropriate Principal Managers must review and


approve in writing any circumstance requiring special permission,
as described in the Code. Copies of these approvals should be
maintained by the company and made available to auditors or
investigating authorities.

Waivers of any provision of this Code must be approved by


the Board of Directors or its designated committee.

MONITORING COMPLIANCE

Employees must take all responsible steps to prevent a Code


violation.

Employees should report suspected Code violations to their


manager or higher level of management, or to the corporate Legal
and Internal Audit Departments. In the case of potential criminal
violations, employees should inform the Compliance Officer.

INVESTIGATIONS

The responsibility for administering the Code, investigating


violations of the Code and determining corrective and disciplinary
action rests jointly with the Chief Executive Officer, Chief
Financial Officer and Compliance Officer, alongwith the Audit
Committee of the Board of Directors.

The Compliance Officer may, with the assistance of the

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company's Internal Audit and Legal Departments, conduct or
manage investigations as deemed appropriate. They will work
together with the employee's managers to recommend corrective
and disciplinary actions for presentation to the Chief Executive
Officer and the Chief Financial Officer. For more information on
the procedures that generally will be followed in the case of
potential Code violations, please refer to the Procedural Guidelines
for the Code of Business Conduct.

If allegations involve criminal conduct, employees should


seek guidance from the Compliance Officer before engaging in any
inquiries.

The Chief Financial Officer will report Code violations and


the corrective actions taken to the Audit Committee of the Board of
Directors.

DISCIPLINARY ACTIONS

The company strives to impose disciplinary action for each


Code violation that fits the nature and particular facts of the
violation. The company uses a system of progressive discipline.
The company generally will issue warnings or letters of reprimand
for less significant, first-time offenses. Violations of a more serious
nature may result in suspension without pay, demotion, loss or
reduction of bonus or option awards, or any combination thereof.
Termination of employment generally is reserved for conduct such
as theft or other violations amounting to a breach of trust, or for
cases where a person has engaged in multiple violations.

Violations of this Code are not the only basis for disciplinary
action. The company has additional policies and procedures
governing conduct.

SIGNATURE AND ACKNOWLEDGMENT

All new associates must sign an acknowledgement form


confirming that they have read the Code and understand its
provisions. Failure to read the Code or to sign an acknowledgement
form, however, does not excuse an associate from the terms of this

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Code.

IT'S UPTO YOU

Administration of the Code is everyone's responsibility.


There are colleagues to help you do the right thing. If you act with
integrity and seek guidance when you are uncertain, you'll be doing
the right thing.

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The Origin of 'Eat Healthy Think Better'
Britannia -the 'biscuit' leader with a history-has withstood the
tests of time. Part of the reason for its success has been its ability to
resonate with the changes in consumer needs-needs that have
varied significantly across its 100+ year epoch. With consumer
democracy reaching new levels, the one common thread to emerge
in recent times has been the shift in lifestyles and a corresponding
awareness of health. People are increasingly becoming conscious
of dietary care and its correlation to wellness and matching the new
pace to their lives with improved nutritional and dietary habits.
This new awareness has seen consumers seeking foods that
complement their lifestyles while offering convenience, variety and
economy, over and above health and nutrition.

Britannia saw the writing on the wall. Its "Swasth Khao Tan
Man Jagao" (Eat Healthy, Think Better) re-position directly
addressed this new trend by promising the new generation a healthy
and nutritious alternative - that was also delightful and tasty.

Thus, the new logo was born, encapsulating the core essence
of Britannia - healthy, nutritious, optimistic - and combining it with
a delightful product range to offer variety and choice to consumers.

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Product Line
As we all are well aware about the company Britannia which
has a huge product line we'll know about some of the products
which are/were famous products of the company below:

Cookies

Britannia's latest symbol of 'Zindagi mein Life' - Britannia


Cookies, is packed with the nourishment of wheat, the richness of
butter and milk, and the lingering flavor of elaichi.

Britannia is the leader in the cookies segment, with the Good


Day at the top end and now Britannia Cookies delighting
consumers at the bottom end of the pyramid.

The Britannia Cookie consumer is seeking to upgrade to a


better taste experience, but at an affordable price since biscuit
category is considered as basic food and often consumed likewise.
Hence Britannia Cookies is priced at Rs.5 for a10 biscuit pack.

The brand's TV commercial starring Deepti Naval as the


mother taps into the universal meaning attached to food, but

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reverse the common perception of the mother as the care giver.
Here, the son packs Britannia Cookies for his mom, in a bid to
ensure that she eats something nourishing.

The strategy was not to play up the pleasurable taste and


indulgence that is normally associated with cookies, but to
highlight the health and nourishment that this product provides,
positioning it as healthy 'khaana'.

Summed up as Britannia Cookies - Tann ko lagey, Mann ko


chuay.

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Tiger

Tiger, launched in 1997, became the largest brand in


Britannia's portfolio in the very first year of its launch and
continues to be so till today. Tiger has grown from strength to
strength and the re-invigoration in June 2005 and more recently, in
Apr 2008 has further helped bolster its growth in the highly
competitive glucose biscuit category.

Tiger is a Glucose biscuit, which comes with the added


goodness of wheat and milk. It is for modern mothers who play an
enabling role for their children to compete in today's world and
thus want the best. Now Tiger Glucose has been fortified with "Iron
Zor" with an attempt towards addressing the Iron Deficiency crisis
the children of India face.

Over the years, Tiger has become the mass-market face of


Britannia symbolising fun and energy in both urban and rural India,
and transcending glucose biscuits.

Tiger Coconut : Delicious Coconut Flavoured Energy


Biscuits, launched in 2001

Tiger Creams : Was Introduced in 2002 at just Rs 5 per


pack. Tiger Cream is now available in Orange, Elaichi, Chocolate,
Pineapple, Strawberry and Butterscotch flavours, and promises to
bring more fun and more energy to children across the country.
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Chota Tiger : Is an extension of brand Tiger launched
nationally in May, 2007. It is mini sized poppable glucose biscuit
with coloured sugar sprinkling. It comes in two variants: Milk
Sparkies and Choco Sparkies

Tiger Banana : Britannia is committed to help secure every


child's right to Growth & Development through good food
everyday. Purposefully taking forward the credo of 'Eat Healthy,
Think Better', we have launched a new variant under our power
brand TIGER - TIGER BANANA - power packed with IRON ZOR
& and with the delightful taste of banana.

IRON ZOR helps make mind sharper and body stronger. A


Rs.4 pack has as much IRON ZOR as that in 1 kg of Banana.

R&D in Britannia has spent considerable time to develop this


nutritious and delightful snack for children.

Britannia Tiger Banana packed with IRON ZOR and goodness of


Banana is accessible to all, being available in convenient packs
priced at Rs.2, Rs.4 and Rs.10.

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Various products under Tiger family

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Good Day

Britannia Good Day was launched in 1986 in two delectable


avatars - Good Day Cashew and Butter. Over the years, new
variants were introduced - Good Day Pista Badam in 1989, Good
Day Chocochips in 2000 and Good Day Choconut in 2004.

This rich cookie enjoys a fan following of consumers across


all ages, loyal to the brand promise of a great taste, evident from
the visibly abundant ingredients. Good Day is among the fastest
growing brands in Britannia's portfolio and it has been the leader in
the cookies category ever since its launch. The brand is
synonymous with everyday treats that infuse happiness into
people's lives.

After two decades of magnificent success; it was time to give


the nation yet another reason to have a good day. Abundance,
goodness, indulgence and now unrestrained joy - that is the
message of this new campaign.

The new TT ad is the uncontrollable expression of the ticket


collector's happiness and joy that is stimulated by consumption of
the cookie, that spreads cheer amongst the people around him
creating an atmosphere of shared joy that's unorchestrated and
straight from the heart. The celebration was taken to the IPL as
Good day cheered along with a million cricket fans in the stadiums,

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each screaming and proclaiming "Ho gaya re Good Day". The
dazzling brilliance of this endeavour, the contagious rhythm needs
to be lived and spread through the nation, making 'Iska toh ho
Gaya Re Good Day' a part of the common lingo and a way of life.

Good Day truly believes laughter and happiness are


infectious, it transcends race, caste creed unifying humanity in an
inclusive emotion.

The brand perseveres to infuse cheer, hearten the nation and


enliven lives. With its rightful place on the front page of The Times
of India, Good Day gifts the nation a priceless treasure, that of
spreading JOY!

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Bourbon

Thick, rich and delicious chocolate packed between two


crunchy chocolate biscuits, topped with sugar crystals - presenting,
the original Bourbon, from the house of Britannia.

India's first and favorite Bourbon's sweet adventure began in


1955. Since then, Bourbon lovers across the country have been
caught opening this chocolate couplet, licking the cream, and
nibbling at the melt-in-your-mouth biscuit, bit by bit. Some have
been witnessed chomping it whole, at one go. Some have been
noted to alternate it with sips of coffee; others team it with lots of
gossip and gupshup, while a few have been observed enjoying it
with a book.
And some have been seen reluctantly sharing their Bourbon.

Whatever the occasion, wherever the hangout, Bourbon


makes for great company. You can grab your very own Nano Pack
or a Pocket Pack. The Hangout Pack is just right for chilling with
friends. Take along a Party Pack for... yes, a party! And the Gift
Pack will surely win you a few brownie points!

So go on, give yourself a happy high with a quick dose of


Britannia Bourbon!

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50-50

With a brand name like 50-50, can the product be anything


but fun? Launched in 1993, 50-50 belongs to the family of crackers
and is considered the "very very tasty tasty" snack.

Britannia 50-50 is the leader in its category with more than


one-third of market share. The versatile and youthful brand
constantly aims to provide a novel and exciting taste experience to
the consumer. As a result, in 2001, the delicious Maska Chaska was
launched as a variant of the original brand and became an instant
success

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Marie Gold

Britannia's oldest brand enjoys a heritage that spans 50 years


- and going strong. In a market swamped with 'Me too' products
Britannia Marie Gold has maintained its strong hold. Today the
ever popular Marie Gold is a loved brand that stands for Tea Time
vitality. It's balanced taste, crispiness and lightness along with the
added vitamins and minerals makes Britannia Marie Gold the
"healthy tea time biscuit". It is the # 1 brand in its category by a
long shot.

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Treat

As a move to consolidate all the individual Cream Treat


offerings under a single umbrella, Britannia launched Treat in
2002. Treat has a range of tasty delights for all kids with yummy
creamy treasures within the biscuit shells. The kids have always
relished unraveling the irresistibly delicious creams hidden inside
the biscuit Britannia Treat offers a wide variety of flavors, such as
the Elaichi, the Fruit Flavored Creams such as Orange, Pineapple,
Mango, and Strawberry, the Jam Filled Centers under the Jim Jam
range, and the Duet Range (biscuits with two flavours of cream
between three layers of biscuit) comprising Strawberry Vanilla and
Duet Strawberry Chocolate.

Britannia Treat has now launched yet another mouth


watering delight under its umbrella. The delicious Fruit Rollz take
the Treat brand beyond the cream biscuits and provides yet another
lip smacking delight to its consumers!

Fruit Rollz are soft rolls filled with the goodness of real
fruits, and provide a healthy yet scrumptious treat to our 'loveable
devils' Treat also introduced its naughty and adorable brand mascot
FUNTOOSH whose primary occupation is mischief! FUNTOOSH
is the guy who will pull off any trick to make sure he gets to eat his
Britannia Treat!

For all you kids who have relished the yummy treasures of
Britannia Treat in exciting flavors, look out for yet another reason

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to celebrate!

Britannia Treat launches a new and exciting combination of


chocolate and caramel in a single bar - TREAT CHOCO GELO.
This unique and never before product is guaranteed to double the
masti and double the fun that you have with Treat.

Treat Choco Gelo has been launched nationally in August,


2007 and is available at an attractive price of just Rs.5/-

So go ahead, open this delicious pack, indulge yourself with


Treat Choco Gelo and enjoy Yummy Chocolate and Gooey
Caramel for "Double Masti ka Double Dose"

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Milk Bikis

Kids may dislike drinking milk, but they love Britannia Milk
Bikis! Milk Bikis has been trusted by mothers as a source of
growth energy of milk and their loyalty to the brand has made it an
integral part of their children's nutrition regimen.

In 1996, Milk Bikis launched a variant called Milk Cream.


These round biscuits come with smiley faces and are full of milk
cream that makes them very popular with children. Milk Cream
also promoted the idea of 'eating milk' in a yummy way, which
makes mothers happy as well.

To keep pace with the demands of the new generation and to


bring milk nutrition to the masses in a delightful form, Milk Bikis,
went one step further in the last quarter of 2006 in providing not
just energy but 'developmental fuel' for children. With a unique and
attractive honeycomb design and an enhanced product experience,
the new biscuit is now fortified with SMART NUTRIENTS 4 vital
vitamins, iron and iodine, proven to aid mental and physical
development in growing kids.

Britannia launched Milk Bikis Almond Cookies a first of


its kind cookie with wholesome goodness of Milk & Almond to
help in growth and development of children.

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In-between-meals snacking is an integral part of a child's
daily food routine as it serves as a hunger filler in between meals.
However, most of the choices available in the market are universal
in nature and largely address the delight needs of all consumers;
they do not necessarily provide the essential 'top up' nutrition that
children should have in their growing years. Research conducted by
Britannia showed that mothers would be happy to have a solution
which is a good balance of nutrition for children in a snack format.

With this in mind, Britannia Industries Ltd., one of India's


most trusted food brands with a diverse portfolio of products in
biscuits, bakery and dairy categories, launched Milk Bikis Almond
Cookie - with the wholesome goodness of Milk & Almond in a
delightful waffle cookie.
Milk Bikis Almond Cookie contains milk and almond
goodness, important for children's growth and development and
comes in a cookie format which children will love to eat. Four Milk
Bikis Almond Cookies have the energy of one glass of milk and
three almonds.

Milk Bikis Almond Cookies have been launched initially in


Tamil Nadu and will be available in Andhra Pradesh. Priced at
Rs.12 per 88.5 gm pack and Rs.25 for 193 gm, Milk Bikis Almond
Cookies are available with a shelf life of six months.

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Time Pass

Before Timepass, Britannia's offering in the salted cracker


category was Snax. Launched in 1999, Snax was promoted as a
tastier base for toppings through edgy advertising.

Then in late 2000, supported by aggressive advertising that


featured the brand as a perfect partner for timepass moments,
Britannia Timepass was launched.

The brand quickly became a leader in Britannia's portfolio


and, consequently, Snax was revamped as a lighter product and
renamed Britannia Timepass Classic Salted. To further the
franchise of the Timepass brand, a variant 'Nimkee' was introduced
in the Eastern market in April 2003, and then taken nationwide
after a favourable response. Judging by its history, the resounding
success of Britannia Timepass will continue to grow.

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Little Heart

Little Hearts was launched in 1993 and targeted the growing


youth segment. A completely unique product, it was the first time
biscuits were retailed in pouch packs like potato wafers. The launch
message introduced a special taste experience that made the
unlikeliest characters - like Dracula and Frankenstein - melt. In
1997, the 'Direct Dil Se' campaign encouraged youngsters to
openly express their feelings. And in 2003, two variants called
Little Hearts Chocolate and Little Hearts Sesame were rolled out
with a campaign "Dil sabka actually sweet hai". With Little Hearts,
Britannia has tasted the sweet taste of success.

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Nice Time

Britannia Nice Time was the pioneer of sugar sprinkled


biscuits in India. This unique product managed to create such a
strong consumer pull that soon there was a rush of pretender
products in the market, clearly indicative of the success of the
concept. Today, Nice Time has a fan base spread across India, and,
particularly, East India, where its consumers have grown up with
the brand. Especially popular amongst children, Britannia Nice
Time has managed to create a loyal franchise for itself and is a
strong brand loved by people of all ages.

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Nutri Choice

In continuation of the promise of "Swasth Khao, Tan Man


Jagao," Britannia introduced NutriChoice range of healthy biscuits
in 1998. The brand is targeted towards overall health and wellness
for adults.

The range has for long comprised of three popular variants,


namely NutriChoice Thin Arrowroot, NutriChoice Cream Cracker
and NutriChoice Digestive.

NutriChoice Thin Arrowroot - An ageless classic


Extremely popular in East India for over 4 decades (where it is
affectionately referred to as Britannia Theen), this brand contains
the benefits of arrowroot known to aid digestion and remove
harmful toxins from the body. Prior to 1998 it was being marketed
as Britannia Jacob's Thin.

NutriChoice Cream Cracker - As nature would have


wanted it to be
Ask any biscuit manufacturer and they will tell you how difficult it
is to make this biscuit, especially with next to nothing sugar, with
NO added colors and flavorings for taste. It is this neutral taste that
makes it an ideal choice to be consumed with hot beverages, dips,
chutneys, and accompaniments.

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NutriChoice Digestive - Delightfully tasty and wholesome
Made with 50% whole-wheat and packed with added fibre (10% of
our daily dietary needs), these delightfully tasty biscuits are
amongst your healthiest bites of the day. In your next visit to a shop
just look out for its Golden-green international pack.

In 2007, NutriChoice SugarOut was launched. NutriChoice


SugarOut is the most novel product range to have been introduced
in the market. The product is not just sweet but tastes great, and yet
contains no added sugar. It is sweetened with "Sucralose," derived
from sugar, which provides the same sweetness as any other
biscuit, without the added calories of sugar.

This range is available in 3 delicious variants namely


Litetime, Chocolate Cream, and Orange Cream, targeted
towards all health sensitive people. It is also relevant for consumers
with sugar- related ailments.

We are confident that you will be pleasantly surprised with the


great tasting and healthy range of NutriChoice. Try one and you'll
know that you've made one smart choice.

NutriChoice 5 Grain

Most consumers believe that to in order to stay healthy one


needs to make certain compromises on some good things in life.
Whether it is missing that extra hour of sleep over early morning
exercise, or eating unappetizing foods over that extra oil-dripping
samosa. At the same time most of us agree that good nutrition
cannot come from one kind of food alone, but from a healthy
combination / assortment of several healthy ingredients put
together. Britannia NutriChoice 5 Grain Biscuits are a perfect
answer to those looking for healthy eating options without as much
making a compromise on taste, or convenience, or health.

Because Britannia NutriChoice 5 Grain biscuits are made


from 5 carefully chosen healthy cereals (Oats that help reduce bad
cholesterol, Corn which promotes heart health, Ragi a good source
of both Calcium as well as Fibre, Rice low in fat, and Wheat that
provides wholesome energy). These biscuits are delicately

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sweetened with natural honey, and come in a unique large oval
shape. It is this large size and the healthy combination of the
ingredients, that make it an ideal hunger buster for those in-
between meals time hunger.

Britannia NutriChoice 5 Grain biscuit pack contains several


small single serve pocket meals packs, so that one is never far away
from pacifying hunger on the move. So whenever you miss your
breakfast, or succumb to those unhealthy evening snacks, you can
relish the goodness of health with Britannia NutriChoice 5 Grain
biscuits.

NutriChoice Classic Lite Cracker - NutriChoice Crackers


have for long been the healthy choice of the discerning consumer.
The popular NutriChoice Cream Cracker has been improved to
make it crispier and tastier and been rechristened as Nutrichoice
Classic Lite Cracker.

NutriChoice Nature Spice Cracker - Now there is more


choice for the discerning cracker consumer. NutriChoice Nature
Spice Crackers are delicately sprinkled with the goodness of
Ajwain and Jeera. Ajwain s benefit with good digestion is
legendary, while each one of us relishes the taste of Jeera. In
addition 0% Sugar is added to these biscuits which delivers the
health promise that Nutrichoice is known for.

NutriChoice Crackers are made by using a special FRESH


BAKE TECHNOLOGY, which ensures that they are completely
free from Cholesterol, harmful Transfats, artificial preservatives,
colors and flavours. They come in an international metalized
packaging, which ensures that the biscuits retain maximum
freshness till the time they are opened.

Nutrichoice Health Starter Kit


2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit . Created for everyone who makes a
New Year resolution to become healthy and does not follow
through on it. The Health Starter Kit contains a range of healthy
biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive,
Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker. It also

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has a one week free pass to Talalkars gym that entitles every
consumer to one week free trial of any Talwalkars (TBVF ltd) gym
across the country.

In addition to this the pack also contains a Fit Sip Sipper and
a fitness chart. All this for only Rs 100.

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History of Biscuits
Sweet or salty. Soft or crunchy. Simple or exotic. Everybody
loves munching on biscuits, but do they know how biscuits began?

The history of biscuits can be traced back to a recipe created


by the Roman chef Apicius, in which "a thick paste of fine wheat
flour was boiled and spread out on a plate. When it had dried and
hardened it was cut up and then fried until crisp, then served with
honey and pepper."

The word 'Biscuit' is derived from the Latin words 'Bis'


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

As people started to explore the globe, biscuits became the


ideal travelling food since they stayed fresh for long periods. The
seafaring age, thus, witnessed the boom of biscuits when these
were sealed in airtight containers to last for months at a time. Hard
track biscuits (earliest version of the biscotti and present-day
crackers) were part of the staple diet of English and American
sailors for many centuries. In fact, the countries which led this
seafaring charge, such as those in Western Europe, are the ones
where biscuits are most popular even today. Biscotti is said to have
been a favorite of Christopher Columbus who discovered America!

Making good biscuits is quite an art, and history bears


testimony to that. During the 17th and 18th Centuries in Europe,
baking was a carefully controlled profession, managed through a
series of 'guilds' or professional associations. To become a baker,
one had to complete years of apprenticeship - working through the
ranks of apprentice, journeyman, and finally master baker. Not only
this, the amount and quality of biscuits baked were also carefully
monitored.

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The English, Scotch and Dutch immigrants originally
brought the first cookies to the United States and they were called
teacakes. They were often flavoured with nothing more than the
finest butter, sometimes with the addition of a few drops of rose
water. Cookies in America were also called by such names as
"jumbles", "plunkets" and "cry babies".

As technology improved during the Industrial Revolution in


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

Interestingly, as time has passed and despite more varieties


becoming available, the essential ingredients of biscuits haven't
changed - like 'soft' wheat flour (which contains less protein than
the flour used to bake bread) sugar, and fats, such as butter and oil.
Today, though they are known by different names the world over,
people agree on one thing - nothing beats the biscuit!

Some interesting facts on the origin of other forms of biscuits:

The recipe for oval shaped cookies (that are also known as
boudoir biscuits, sponge biscuits, sponge fingers, Naples biscuits
and Savoy biscuits) has changed little in 900 years and dates back
to the house of Savoy in the 11th century France. Peter the Great of
Russia seems to have enjoyed an oval-shaped cookie called "lady
fingers" when visiting Louis XV of France.

The macaroon - a small round cookie with crisp crust and a


soft interior - seems to have originated in an Italian monastery in
1792 during the French Revolution.

SPRING-uhr-lee, have been traditional Christmas cookies in


Austria and Bavaria for centuries. They are made from a simple
egg, flour and sugar dough and are usually rectangular in shape.
These cookies are made with a leavening agent called ammonium
carbonate and baking ammonia.

The inspiration for fortune cookies dates back to the 12th

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and 13th Centuries, when Chinese soldiers slipped rice paper
messages into moon cakes to help co-ordinate their defense against
Mongolian invaders.

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PRODUCTION
Manufacturing Process:
Short Dough biscuits manufacturing is a process involving
three phase of process line
! Pre Baking
! Baking
! Post Baking

The main raw materials are wheat flour, sugar, vegetable fat,
Food grade additives, etc. Dough is prepared using basic required
ingredients then the dough is sheeted for continuous sheeter and
cuted for required size and shapes. After this process shaped
biscuits are baked in the oven up to desired temperature and
removed through conveyor here oil is sprayed on the biscuit to
keep them shiny and more appealing. After this process the biscuits
are stacked using stacking unit and sent to packing machine for
required type of packing.

Machine Model List


Pre Baking machines

! Sugar Grinder unit


! Sugar Syrup Machine
! Flour sifter
! Horizontal Dough mixer
! Horizontal cut and Lay Laminator
! Triple roll Sheeter: (Three stage sheeter)
! Rotary Molding Machine
! Salt / Sugar Sprinkler

Baking machine

! Biscuit baking oven tunnel type

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Post baking machine

! Turning Table
! Cooling conveyor
! Oil Spray Machines
! Stacker Machine

Packaging machines:

! Automatic Horizontal Flow Wrap Machine


! Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack)
! Automatic, On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack)
! Automatic, On Edge, Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)

Available Plant Capacity: - 200 Kg per hour to 4000Kg per hour.

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Biscuit Productin Line

Biscuit production line consists of following equipments


with brief description:-

Mixers
All ingredients are mixed into mixers to prepare dough with
desired characteristics. Normally two stage mixing is done in
biscuit production One with rapid slow speed and second stage
with rapid speed hence one select a dual speed mixer .

Dough Elevator or Dough Tipper


Dough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower
to the tipper or dough bowl is carried to certain height and then
tilted to decant the bowl into laminator hopper .

Dough Laminator
Laminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll.
Laminators have sets of roller where this dough is acted upon and
are converted into dough sheet.

Gauge Rolls

These gauge rolls have set of cylindrical rollers which rotate


in reverse direction so as to give push to the next gauge rolls. Three
stand to four stand of gauge rolls are used in normal biscuit
production line. Speed of rolls is set as per the baking time and
increases as we proceed further.

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Moulding or Cutter Unit
These are equipment which cuts the dough sheet into desired
shape and size. Plant out put are calculated as per the design of the
moulder or cutter. These cutters or moulders have dies, cups or
inserts which are fixed on the cavities or surface of the moulder or
cutter.
Now days engraved moulders and cutters are available.
Moulders are now designed in rings instead of single piece which
helps in maintenance or changing damaged cups.
Molder are used for short dough where as cutters are used for hard
dough variety

Scrap return conveyor


These conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste .

Swivel Panner
Swivel panner is installed at the feed end of oven where it
centre's the dough piece entrance on baking oven band it has swivel
arrangement on which it balances the web or centres the web so
that wet dough pieces enter s oven in straight line .

Baking Oven
Dough pieces then enters oven and travels on wire band for
baking. Burners generate heat which is circulated through ducts or
pipelines to bake wet dough pieces. Length and width of oven are
designed as per the capacity required. Oven speed is adjusted as per
the standards baking time for particular variety

Stripper Conveyor
Stripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of
any surface when hot . A stripper conveyor has wire mesh which
carries these hot baked biscuit.

Cooling Conveyor
These conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from
oven. Normally they 1.5 -2 times of oven length.

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Magnetic Stacker
Stacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process. These
biscuits are made to pass of plates which act as guides which makes
these biscuits to fall into space between the guides.

Packing Table
Biscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are
fed into feeding chutes manually by operators.

Packing Machine
Biscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type, on the edge
and cream sandwich type. Horizontal flow wrap machines are
mostly used to pack with flexible packaging.

Dough Separating Device

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Short Dough Biscuits

Short dough biscuits are produced on lines, which consist of


a sheeter and calibration rollers. After producing an endless dough
sheet, the desired dough blanks are cut by a single roller or double
roller system. The resulting network of scrap dough is fed back to
the sheeter.

The blanks are baked in a hybrid oven (directly heated in


feed combined with radiation, which can be provided with or
without convection) on a wire mesh band.

Dough Mixing

High Speed Mixer(HSM)


The HSM is used for preparing dough's for the production of
dressed, molded, root-pressed (queen) and wire-cut biscuits, hard
and semi-hard biscuits as well as crackers.

HSM - Technical Data


! Robust steel construction, low noise, vibration less, stainless
steel panelling.
! Kneading arms made of special steel, supported on both

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sides.
! All parts contacting dough made of non-rusting material.
! Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation, up to 1500l =
approx. 900 kg dough/batch.
! Operating panel and switch cabinet integrated in machine
frame.

Sheeter

Triomat Sheeter

Preomat Sheeter
Three-Roller-Sheeter TRIOMAT

The TRIOMAT machines are used to produce uniform and


homogenous dough bands of all common kinds of dough.

TRIOMAT - Technical Data

! All-steel two-plate construction.


! Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller.
! Dough band rolled out by upper and lower calibrating roller.
! Conversion to calibrating machine possible by lowering the

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fluted roller.
! Roller gap adjusted by motor with digital display.
! Minimum dough band thicknesses of about 8-10 mm
possible.
Special hopper arrangement: return dough always fed to the bottom
of the dough band, therefore no surface color differences.

Four-Roller-Sheeter PREOMAT

The PREOMAT machines serve to produce dough bands for


rotary-cut biscuits or for feeding a biscuit molding machine,
respectively.

PREOMAT - Technical Data

! All-steel two-plate construction.


! Fluted roller and calibration roller pairs with separate drives.
! Roller gap adjusted by motor with digital display.
! Fluted roller pair speed controlled by microprocessor.
! Frequency-controlled three-phase motors as drives.
! Minimum dough band thickness of about 4 mm possible.
Special hopper arrangement: return dough always fed to the bottom
of the dough band, therefore no surface color differences.

Cutting Machines

DuoCut
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Twin Roller Cutting Machine DUOCUT
The DUOCUT is used for the production of short dough
biscuits, crackers and cocktail articles and can also be employed as
single roller cutting machine.

DUOCUT - Technical Data


! All-steel two-plate construction.
! Independent drives for each roller, cutting band and optional
moistening device.
! Position of cutting rollers adjustable to each other.
! Split bearings for simple installation and removal of the
rollers.
! Bearing design allows use of several cutting rollers with
different diameters.
! Cutting band with pneumatic band tensioning and band
centring.

! Pneumatic lowering of rubber roller for quick production


interruption.
! On request available with integrated roller exchange system.

RotoCut

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ROTOCUT
The ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller.

ROTOCUT - Technical Data


! Centrally driven cutting band.
! Bearing support design allows use of several cutting rollers
with different diameters.
! Lowering of cutting roller by hand wheel.
! Product changeover facilitated by simple removal and
installation of cutting roller.
! Driven by frequency-controlled three-phase motor.

Biscuit Ovens
The Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits, crackers and cocktail
biscuits, Swiss rolls or layer cakes. The most suitable oven type for
a certain product and for certain production conditions can be
selected from different baking systems. Moreover, it is also
possible to combine two different oven systems to a hybrid oven.
All ovens are available in working widths from 800 to 1600 mm.

Multivariant Oven
MULTIVARIANT OVEN - Technical Data
! Indirectly heated radiant oven.
! Natural or liquid gas.
! 2.0 m long modules with efficient rock wool insulation,
welded baking chambers of carbon steel bolted to each other.

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! Automatic ignition, burner monitoring and temperature
control.
! Optional addition of convection: the advantages of indirect
radiant heating (good product development, universally applicable,
high moisture possible) are combined with those of convection
(shorter baking times, good drying, low baking temperatures,
uniform product colouring).

Cyclotherm Oven

CYCLOTHERM OVEN - Technical Data


! Indirect heating by natural or liquid gas or by heating oil.
! 2.0 m long modules with efficient rock wool insulation,
welded baking chambers of carbon steel bolted to each other.
! Automatic ignition, burner monitoring and temperature
control.
! Centrally arranged high-capacity burner in each control
zone.
! Heating of gases by a closed circulation system in the burner
chamber; gases are passed through ducts into radiators above and
below the baking band.

GasMultiburner Oven
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GAS MULTI-BURNER OVEN - Technical Data
! Directly heated radiant oven.
! Suitable for natural or liquid gas.
! 2.0 m long modules with efficient rock wool insulation,
welded baking chambers of carbon steel bolted to each other.
! Automatic ignition, burner monitoring and temperature
control.
! 3-zone-burners (adjustable across the width) are specifically
employed for uniform distribution of moisture and uniform product
colouring across the width.

ElectricMultiburner Oven
ELECTRIC MULTI-BURNER OVEN - Technical Data
! Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded
resistance heating wires made of highly heat-resistant
material.
! 2.0 m long modules with efficient rock wool insulation,
welded baking chambers of carbon steel bolted to each other.
! Automatic ignition, burner monitoring and temperature
control.
! Infinitely variable thyristor control guarantees exact
agreement of actual values with the set values.
! Steam extraction and discharge adjustable by manually
operated dampers (placed every 5 m).

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Ingredients
The most common ingredients used in baking biscuits are
following:

Flour
Yeast
Fat
Sugar
Vitamin C
Baking Soda
Baking Powder
Salt
Hydrogenated Vegetable Oil
Skimmed Milk Powder
Ammonium Chloride

1. FLOUR :- This provides most of the baked item. For bread


baking, the flour should be a wheat flour which is high in gluten
(protein) as this is substance that gives bread its fine texture and
support the ingredients during rising. The word flour refers to the
powder obtained from grinding a cereal grain. Although other
flours (e.g. Rye flour) are used in baking, wheat flour is by far the
most common and is the only one that will be discussed here. All
flours are composed largely from starch and protein, but wheat
flour is distinctive in that it has very high levels of a class of
proteins known collectively as gluten (8-14%). When a dough is
made from wheat flour and water, the gluten develops into a thick,
cohesive, elastic mass. When placed in oven, it puffs up to many
times of its original volume and sets with a light, airy texture. This
characteristic enables gluten to provide the structure in baked
goods, cakes and bread. In the network of gluten the starch
granules are embedded rather like a system of bricks in mortar. The
characteristic and general quality of the flour depend on:
! The wheat variety and conditions under which the wheat has
grown. This affects the quality and quantity of gluten in the grain.

! The milling process. This determines the degree of


separation of the bran and endosperm, as well as the particle size of
the flour, an important factor in cake flour.
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! Additives and special treatments used by the miller to
produce flour mixes with special characteristics. In New Zealand,
additives cannot be used in products sold as flour, but they are
commonly used by millers to make up premixes for particular
applications.

2. YEAST :- Yeast is a plant that feeds on starch and sugars.


Releasing CO2, alcohol and sugar. The CO2 bubbles give the dough
a light, airy tecture. Yeast is made up of many tiny, singe-celled
plants, which grow bu budding, each bud breaking away from the
o
parent cell and warmth (Optimum 25-30 C), moisture and food
(starch plus a small amount of sugar). Refrigeration slows down the
growth so that yeast can be kept for a limited period of time. When
the yeast is used, the conditions and the ls should be kept lukewarm
to obtain the best results. As soon as the yeast has been added to the
dough or batter, the yeast begins to feed on starch in the mixture,
forming sugar, alcohol and carbon dioxide. The bubbles of CO2
cause the dough to expand("rise"). The dough must be "kneaded"
throughly to distribute the bubbles evenly and then left to rise
again, usually to about double its original volume. If the mixture is
left too long, acid produced by the oxidation of the alcohol causes
the product to taste sour.

3.FAT :- Fat gives a softer texture and helps prevent the CO2
bubbles from escaping from the mixture too soon. Fat has five
major roles in baking as outlined below. How well it will perform
each of these functions depends largely on the "slip point" - the
temperature at which the fat just begins to melt. In general the slip
o
point should be at least 5 C above the proving temperature of the
dough.

The Role of fat are as follows:

Shortening

Fat weakens or 'shortens' a dough by weakening its gluten


network, resulting in the baked product being softer, breaking
easily and having a more tender mouth feel.

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Creaming

Fat can trap air during beating and mixing, producing a


batter that consists of masses of tiny air bubbles trapped within
droplets of fat. This is very important in cake baking in which it is
these air bubbles that expand during baking forming a light airy
structure.

Layering

In puffy pastry fats which are soft over a wide temperature


range are used. These can be spread between pastry layers and will
separate them during cooking giving a layered pastry.

Flavor

Usually the fats used should have a bland flavor to prevent


them from changing the flavor of the finished product, but
occasionally fats are chosen on the basis of their flavor- e.g. Using
butter for particular baked goods and lard for meat pie pastry. In
addition, the fat chosen needs to be able to form an emulsion with
other ingredients in the batter or dough.

4. SUGAR :- Sugar provides a direct food source for the


yeast, improving its action,. Sugar is most commonly thought of as
a sweetener, but in baked goods it is also involved in several other
processes. Sugar undergoes a series of complex browning reactions
o
above 160 C, and the products of these form the brown crust of
many baked goods. The reactions are known as mallard reactions,
and are essentially amino acid-catallysed caramelisation reactions
in which a sugar aldehyde or ketone is converted to an unsaturated
aldehyde or ketone.
In addition, 0.5-0.75% of sugar increases the rate of
fermentation for fermented goods (i.e breads) by giving the yeast
more sugar to work on. In non-fermented goods such as biscuits,
large quantities if sugar can be added. This improves the keeping
quality of the biscuits as well as sweetening them. The sugar
usually used is pure sucrose as castor sugar, 1A sugar or icing
sugar. Occasionally impure forms such as golden syrup, honey and
brown sugar are used to give the baking a particular flavor.

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5. VITAMIN C :- Also shortens the time needed for dough to
"mature". It has been established from many experiments that the
addition of a small amount (up to 100ppm) of vitamin C also
shortens the time needed for the dough to mature. This is because
ascorbic acid catalyzes the gluten cross linking reactions to form a
more extensible, elastic, strong network.

6. BAKING SODA:- Releases CO2 according to equation

2NaHCO3 Na2CO3 + CO2 + H2O


Since the material is relatively cheap and stable to store, it would
seem to be an excellent agent for the production of CO2. The above
equation, however, also illustrates the disadvantages of the
material. When used on its own, only half the available CO2 is
released and more seriously, the sodium carbonate produced is
strongly alkaline and gives the baked product a bitter, "soapy" taste
and a yellow color. The digestion of such products also tends to be
somewhere between embarrassing and traumatic, since the Na2CO3
reacts with the HCl in the stomach to produce the other half of the
available CO2. For the above reasons, it must be stressed that
sodium bicarbonate is very rarely used on its own, but generally
mixed with some acidic material such as cream of tartar, honey,
cocoa or golden syrup (e.g. Treacle and baking soda are used
together in baking gingerbread men). To avoid an imbalance
between the acidic and basic materials, i.e an incorrect pH baking
powder is more commonly used. However, as this also produces a
strong base, Na2CO3, which has to be neutralized, baking powder is
usually instead.

7. BAKING POWDER :- Baking powder is baking soda with


acid added. This neutralizes the base and produces more CO2
according to the equation :

8. SALT :- Salt adds flavor and strengthens soft fat and sugar
mixtures. Salt is added to enhance the flavor of cakes and breads
and to "toughen up" the soft mixture of fat and sugar.

NaHCO3 + H+ Na+ + H2O + CO2

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9. HYDROGENATED VEGETABLE OIL :- (HVO)
Main function of HVO is to retain the moisture inside the
dough. Gives smoothness to the bite.

10. SKIMMED MILK POWDER :- (SMP) Main function of


SMP is to give flavor to the product and sweeten the product.

11. AMMONIUM CHLORIDE :- Ammonium chloride


provides nitrogen which is used to activate yeast in presence of
water and sugar.

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PRODUCTION process of Biscuits

Ingredients Mixing Forming


Ingredients Mixers Laminators
Addition Mixing Time Gauge Rolls
Sugar Solution Water Sheet Reduction
Preparation of Creaming Cutter
Flour Dough Moulders
Fat consistency Shape and Size
Ammonia Biscuits grinders of dough piece
Additives
Flour sifters
sugar grinders

Packaging
Cooling Baking
PPM
Metal Deduction Coiling Time Baking Ovens
Stackers Cooling Baking Time
Feeding Chute Conveyors Temperature
Horizontal flow Burners
form warp Steam Extraction
Vertical filling Oven Output
Cream
sandwiching
Wrapper
Printing
Carton Sealing

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Mixing
Mixing is a precess were all the ingredients are put together
in right proportion for dough formation. These ingredients are then
fed into mixers where mixing is done and dough is prepared for
molding. Major ingredients are flour. Fat. Sugar and others as per
the product one would like to have.

These ingredients are used in varying proportions to produce


different products. As well as home baking, these include
commercial cake mixes and breads. The commercial products and
commercially produced raw ingredients are monitored in
laboratories to ensure consistent quality and the New Zealand
Institute For Crop and Food Research in Christchurch provides
services for monitoring the composition of all wheat grown in New
Zealand and all flours produced at flour mills. The delicious smell,
and the delicious baking are produced as a result of the interaction
of various chemical and physical processes that can be adjusted by
the cook to create a great variety of products.
Mixing can be done by following three types:
1. One Stage Mixing
2. Two Stage Mixing
3. Three Stage Mixing

1. One Stage Mixing :- This type of mixing is used where all


ingredients and water are added once. Mixing is allowed till
satisfactory dough is prepared. Normally this type of mixing is
used for hard dough. This is also called All in One mixing.

2. Two Stage Mixing :-

First Stage is creaming. In this stage all ingredients are added


with water and mixed 4-5 minutes except flour.

In second stage flour and chemicals are mixed with creaming


product to form a consistent dough.

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3. Three Stage Mixing :-
In first stage fat, sugar with other ingredients like milk,
chocolate, malt, honey etc are mixed and cream is prepared with
portion of water.

In second stage salt, chemicals and flavor with color are


mixed with water

In third stage flour with water is then added to the prepared


cream and mixed till satisfactory dough is prepared.

MIXING PROCESS :-
It has following characteristics which have been monitored
for better results

Mixing Time : Normally any mixing could be achieved within 15-


25 minutes. Much depends on mixing speed of mixer, flour
characteristics or temperatures required for dough.

Dough Temperature: Very important factor the temperature


ranges between 35oC - 42oC as per biscuit variety.

Dough Consistency: This is done manually by checking dough


and stretching the dough it should not break neither by bakers by
trial and error method.

For cracker variety dough are prepared which have


additional ingredients like yeast, and such dough are kept for 10 -
24 hrs.

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Forming
In forming section the dough is passed through several
rollers to form sheet, these sheets are than converted into one
uniform sheet of desired thickness it is normally 5-6 mm thick.
Molders and cutters are used to cut sheet or convert dough
into desired shape and size.

FORMING PROCESS :-

Laminators :-Dough after mixing is tipped into laminators hoppers


are with some mechanical/pneumatic tilting. There are two types of
laminators.

Horizontal Type Laminators:- If space is not the constraint


then horizontal type laminators are the best selection as the
maintenance and repairs are easily done. The lamination and the
controls are visible. Changing webs and rolls are very easy.
Pneumatics and servo motors are used in now modern day
laminators for automated speed to be synchronized with rest of the
plant which is around 11-14 sheets per batch.

Vertical Type Laminators:- Vertical type laminators have


been there for very long its useful if space is a constraint. Dough is
passed through three stage rollers and after lamination of sheet it is
cut into sheets which are then carried to rollers through inclined
webs.

Gauge Roll Stands:- Reduction in sheet is achieved


through numerous gauge roll stands. Popular are three gauge rolls
or four stand gauge rolls. Reduction are achieved in stages an not to
create too much stress on the sheet, web is provided in between for
relaxation even an additional web is provided prior to cutter to
release stress from dough sheet. Best results are achieved through
four stand gauge rolls. These gauge roll are of different diameter
depending upon the plant capacity or requirement the different
diameters are 6", 8", 10", 12" & 14". Speed is set as per the cutter

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RPM. Gauge roll speed has to be increased in every stand so as to
maintain the flow of sheets.

Dough Sheet Conditioning:- Dough sheet conditioning is


done as per the ambient conditions in the plant.
Steam Spray : To moist the web surface.
Blower : To dry the dough surface.

Flour Dusting:- To dry the wet surface of the dough. This


process is mainly for cutting variety.

Toppings:- Toppings are done through mechanical, vibratory


or spray, a hopper is placed above the plant line after the cutter. The
toppings could be milk, salt, sugar or cashew, pista bits.

Rotary Cutter:- Rotary cutters consists of cups which are


attached to the cutter shell. This shell is then fixed to the shaft and
drive mechanism. Two types of rollers are popular One is complete
on mold shell where cups are attached in the cavity designed for
with dowel pins. Second concept is also very popular when shell
has several rings fitted over it. This helps in easy removal of
damaged part and is also very helpful in taking various trials.
Cutter is coupled with the rubber of shore hardness of approx 80-
85%. Rubber roller or the pressure roller helps in releasing wet
biscuits.

RPM:- Rotary cutter speed is set as per plant requirement,


baking time and variety of biscuit.

Band Coverage Efficiency:- It is ratio of total surface area


of cutter-moduler/no biscuit cups.

Molding Roller:- It is applied for short dough, The dough is


prepared in lumps these are then fed to die roll through either
reciprocating conveyor to the hopper or a rotary conveyor which
allows these dough crumbs to spread uniformly on the die roller
surface. These Die roller have dies engraved into it. Dough pieces
are then released by feed roller which pushes the dough into the
dies.

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Baking
Wet dough pieces of desired weight and shape are then
passed on to oven band through swivel panner web. Ovens are of
different types classified into following categories:

A. Type of Heating
B. Type of Fuel
C. Type of Design
D. Width of Oven Band
E. Number of Zones

Heat is transferred to biscuit on band through all the three


ways of heat transfer i.e conduction, convection, radiation.
Following are the chemical and physical changes which occurs 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
4. Water converted into steam

Escape of gases and steam would result in collapse of biscuit


structure, hence these are passed onto different zones with gradual
increase or decrease of temperature. Zones are classified as:

1. Heating Zone
2. Baking Zone
3. Coloring Zone

Chemical Changes

1. Gas formation
2. Starch gelatization
3. Protein changes

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4. Caramelisaion of sugar
5. Dexterisation

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Cooling
Cooling process is as important than any other process,
When biscuits comes out from oven the temperature of biscuits are
o
around 70-95 C, these biscuits can be cooled by letting it travel for
distance of 1.5 times of baking time/ So if you have a oven of 200ft
then the conveyor length would be approx 350ft. In some places
forced cooling is also done due to space constrain or for special
features. Cooling brings temperature to room temperature for
handling of biscuits for packing.

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Packaging
Biscuits are fed into packing machines in continuos stacks
this is either manual or with the help of auto feeders with help of
feeding chutes. Biscuits are fed into packing machines in
continuous stacks this is achieved through stacker which converts
free flowing biscuits into uniform stacks. These are done through
guidelines which could be adjusted as per type of biscuits.

Major functions/advantages of packaging are:

! Protect from mechanical damage in transit, loading and


unloading.
! Protect from loss of moisture and any foreign odor
contaminations.
! Protect from foreign body infestation.
! Legal compliance for values and ingredients for consumers.
! Advertisement

Biscuits are wrapped with packing machines and wrappers are


sealed as long and ends. These are sealed with help of heaters.
Coders are synchronized with machine speed to print details to the
packing material. Packs could be of various size and shape. Popular
are pillow pack and family pack with weight ranging from 25gms
to 400gms. These packs are then put into cartons are been taped by
passing through carton taping machines. Now biscuits are ready for
dispatch.

Various type of packing material is used in biscuit industry.

Primary packaging: Laminate/Wrapper, wax paper and Bopp


films. These are tailored made for various packs where the cut off
length and width are decided prior to packing material production.
Basic properties for laminates and corrugated boxes are Bursting
strength, GSM and thickness of films measured in microns values
varies from one product to other.
Selections have to be done on above parameter. Primary

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function of packaging is protecting biscuit from foreign body
infestation, increasing shelf life, product and manufacturer into and
transportation.

Technological innovation has made possible to have various


shapes, sizes and colors for biscuit packaging. The important
groups of packaging material are as follows:-

Carton Boxes.
Display Boxes.
Bopp Items.
Wrapper.
Stickers.
Bopp Tapes.
Tear Tapes.
Shrink Films.
Polypropylene Sheets.
Pouches.
PVC Trays
Wax Papers.

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Questionnaire (External)
This Questionnaire is for Academic purpose only and
all the information revealed is collected by the trainee
himself it has no link to the activities of the company.

Q. 1 What come to your mind when you think of biscuits.


___________________________________________
_______________________________________________

Q.2 What do you look for when you purchase biscuits and
cereals? Please rate them on a scale of 1 to 5. (1being least
important and 5 being Most Important).

Attributes Importance
Taste
Crispiness
Size
Nutrition Value
Ingredients
Shape
Color
Flavor
Price
Brand Name

Q. 3 What is the major buying factors(tick any one).

Price Brand Name

Availability Discounts
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Q.4 Which type of biscuits do you like to have(tick any
one)?

Wafers Cream

Cookies Plain

Q.5 Where do you make your purchase(tick any one)?

Super Market Retailer

College Canteen Any Other

Q.6 How many packets of Biscuits do you consume per

Week Month

Q.7 Which Brand do you prefer(tick any one)?

Britannia Parle

Kellogg's Lancer

Q.8 If retailer gives you some other brand(other than you


specified above) will you buy?

Yes No

Q.9 What improvements would you suggest for Britannia


Biscuits?
_______________________________________________
_______________________________________________
_______________________________________________

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Please tell us something about yourself

Name :

Age(yrs) :
(10-15)
(15-20)
(20-25)
(25 & above)

Sex(M/F) :

Household Income Level :


(12000-15000)
(15000-20000)
(20000-25000)
(25000 & above)

Occupation :

Address :

Arpit's Page # 84
Questionnaire (Internal)

This Questionnaire is for Academic purpose only and


all the information revealed is collected by the trainee
himself it has no link to the activities of the company.

Q. 1 As an employee of Britannia Industries Ltd. are you


satisfied with the working conditions here.

Yes No

27%

Yes
No

73%

Q.2 What more do you expect from the company?


_______________________________________________
_______________________________________________

Q.3 How much time do you spend in the company, daily(in


hrs)?
6-8 8-10

10-12 12 & above


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7%

17%
6-8 Hrs
46% 8-10 Hrs
10-12 Hrs
12 & Above Hrs

30%

Q.4 What do you think you get paid enough according to


the working time spent?

Yes No

32%

Yes
No

68%

Q.5 Are you satisfied with the services at the medical


checkup conducted by the organization?

Yes No

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12%

Yes
No

88%

Q.6 Is there anyone from your family working with


"Britannia Industries Ltd." presently?

Yes No

17%

Yes
No

83%

Q.7 Would you prefer any of your relative to work with


"Britannia Industries Ltd."?

Yes No

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33%

Yes
No

67%

Q.8 Are you satisfied with the grievance resolution


procedure of "Britannia Industries Ltd."?

Yes No

Partially Partially
Satisfied Unsatisfied

16%

31%
Yes
No
Partially Satisfied
Partially Unsatisfied
37%
16%

* The data revealed here is collected by the trainee and


has no link with the activities of the organization and is
collected only for academic purpose, it has nothing to do
with the organization's actual activities.

Arpit's Page # 88
Findings

While pursuing my training with "Britannia


Industries Ltd." I came to know across various factors
affecting the production system of a company running at a
huge scale and after observing all the facts and figures I
finally came to one huge question...

"How do they manage it all round the clock, 24x7???"

And the answer to this question is very simple and well


known, "It all depends on coordination and team work"

Let me start from the very first day of my experience


with the brand as a trainee, I met with the HR Manager Mr.
Mayank Shreevastav he taught me a lot of things about the
company itself and also about the corporate world to which
I was unaware till that time, his valuable suggestions and
piece of knowledge also helped me a lot in completing my
project work, He showed me the way to his company's
Production Manager Mr. Anil Anand who was also my
external guide for the period of my study and training he
showed me all the departments and machines related to the
production system in a step by step and well planned
manner and it all took days as he also showed me the
process at every stage for ex. Laboratory tests of the raw
material, cleaning the machines, preparing the mixers,
cutters and molders, preparing the die for printing on the
package, as I was new to the organization I was not
allowed there to wander on my own so I have to go where
ever he took me or his presence was necessary at the point
of time which helped me to know about the break downs
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and other problems faced in producing biscuits and also
the method of resolving the problem which is impossible
to know through books or in lectures. Well, through my
period of study I saw a lot of things to which I'll explain
now.

Quality Assurance:- Now after being present at the


company's production place as a trainee I can freely say
that at "Britannia" the quality is at the highest priority
starting from the very beginning when the raw material
reaches its destination from various parts of the country as
well as globe its first of all tested for the quality assurance
and it is only than allowed to get into the production
process when it is passed in the laboratory and if it fails the
tests and very strictly followed guidelines of quality the
whole consignment is rejected and is returned back to the
supplier and a new and fresh consignment is ordered.

Skilled and experienced employees:- All te employees


working at the "Britannia" are highly skilled and
experienced not only with respect to their respective work
assigned to them but they are also very handy with the
other related tasks and works required.

Clean and healthy Environment:- Its not just about the


raw material and the employees which makes the product
good, one of the very important factor related to quality
production is environment at the work place, the work
place at "Britannia" is above average and the environment
there is very friendly all the employees work as a team
which results not in just good quality product but the rate
of error becomes very low and the rate of use of resource is
increased.

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Right man for the right job:- This policy is very helpful
at every workplace to get the best from the human resource
as if a person is assigned to a job to which he is very handy
and better than other the efficiency of the individual as
well as organization increases.

State of the Art Technology:- The manufacturing unit is


equipped with the latest available technology and the best
available machines are used to produce the best quality
biscuits, latest available computer software is used to put a
check on machines and the production quality which
doesn't just help in producing good quality products but
also reduces the per unit economic cost and the wastage of
precious resources is low which helps to increase the
efficiency of the organization as a whole.

Team Work:- Above all is the team work, all the


employees at "Britannia" works as a team and the result is
in front of us, a well known brand with a variety of
products available for the customer and with the major
market share in every segment where the products of the
brand is available and the trust on the brand proves it all, in
a way or the other we all use "Britannia" may it start with
the breakfast at morning at our home or the tea time in the
noon at office/colleges we all uses it in a way or the which
proves that the team work of the employees works in the
best manner it can, not only at the production line but also
at the distribution and marketing hand which makes it
possible for the product to reach to the end customer or
consumer no matter what the situation is.

Limitations: As we all know that noone and nothing is


perfect, so is the "Britannia Industries Ltd." even this huge

Arpit's Page # 91
giant of FMCG sector have limitations and is not flawless,
the total production process has some minute problems
here and there all the time some time the manual and some
time technical but it doesn't states that the organization is
not working properly, as I felt that the pungent smell goes
directly to brain and is some times reduced by masks but
the masks provided by the organization are not able to
provide a complete cover to the smell, which needs an
attention, the waste under process material is not able to
use again i.e it cannot be recycled as once all the
ingredients are mixed they cannot be separated after
preparation of the dough for this reason the organization
has set a strict ratio of only 3% wastage but it still needs to
be reviewed, as the temperature of ovens is very high and
is up to 1000C so the temperature of workplace around the
ovens also increases and the employees working there
needs a proper ventilation/cooling system right over their
head, which is provided to them but doesn't seems proper
to me.

Arpit's Page # 92
Bibliography

All the data collected for generating this project


report is collected from different sources, these are:

! Company Journals
! Data provided by the project coordinator
! Notice Board @ the Pantnagar Unit

Company websites:-
www.britannia.co.in
www.britannialiving.co.uk

Other websites:
www.biscuits.eu.com
www.wikipedia.org

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