Professional Documents
Culture Documents
Summer Training Project
Summer Training Project
Summer Training Project
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.
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.
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.
ARPIT NAGAR
BBA (2008-11)
Arpit's
Page # 04
CONTENT SHEET
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
9. Bibliography 93
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.
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.
WEBSITE:- www.britannia.co.in
Arpit's Page # 07
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.
Work Places
Arpit's Page # 10
BOARD OF DIRECTORS
Name Designation
Arpit's Page # 11
Management Team
Arpit's Page # 12
Gautam Banarjee General Manager(Materials)
Arpit's Page # 13
Milestones for the Company
Arpit's Page # 14
third Indian a Britannia consumer'
Arpit's Page # 15
Volumes cross 3,00,000 tons of biscuits
Arpit's Page # 16
Britannia launched Iron fortified 'Tiger Banana'
biscuits, 'Good Day Classic Cookies', Low Fat Dahi
and renovated 'MarieGold'.
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:
2. Workplace Responsibilities
Arpit's Page # 18
3. Representing Britannia to Customers and Other External
Constituencies
4. Privacy / Confidentiality
Arpit's Page # 19
ADMINISTRATION OF THE CODE
DISTRIBUTION
APPROVALS
MONITORING COMPLIANCE
INVESTIGATIONS
Arpit's Page # 20
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.
DISCIPLINARY ACTIONS
Violations of this Code are not the only basis for disciplinary
action. The company has additional policies and procedures
governing conduct.
Arpit's Page # 21
Code.
Arpit's Page # 22
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.
Arpit's Page # 23
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
Arpit's Page # 24
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.
Arpit's Page # 25
Tiger
Arpit's Page # 27
Various products under Tiger family
Arpit's Page # 28
Good Day
Arpit's Page # 29
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.
Arpit's Page # 30
Arpit's Page # 31
Bourbon
Arpit's Page # 32
Arpit's Page # 33
50-50
Arpit's Page # 34
Arpit's Page # 35
Marie Gold
Arpit's Page # 36
Arpit's Page # 37
Treat
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
Arpit's Page # 38
to celebrate!
Arpit's Page # 39
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.
Arpit's Page # 40
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.
Arpit's Page # 41
Arpit's Page # 42
Time Pass
Arpit's Page # 43
Arpit's Page # 44
Little Heart
Arpit's Page # 45
Nice Time
Arpit's Page # 46
Nutri Choice
Arpit's Page # 47
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.
NutriChoice 5 Grain
Arpit's Page # 48
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.
Arpit's Page # 49
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.
Arpit's Page # 50
Arpit's Page # 51
History of Biscuits
Sweet or salty. Soft or crunchy. Simple or exotic. Everybody
loves munching on biscuits, but do they know how biscuits began?
Arpit's Page # 52
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".
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.
Arpit's Page # 53
and 13th Centuries, when Chinese soldiers slipped rice paper
messages into moon cakes to help co-ordinate their defense against
Mongolian invaders.
Arpit's Page # 54
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.
Baking machine
Arpit's Page # 55
Post baking machine
! Turning Table
! Cooling conveyor
! Oil Spray Machines
! Stacker Machine
Packaging machines:
Arpit's Page # 56
Biscuit Productin Line
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 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
Arpit's Page # 57
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
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.
Arpit's Page # 58
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.
Arpit's Page # 59
Short Dough Biscuits
Dough Mixing
Arpit's Page # 60
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
Arpit's Page # 61
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
Cutting Machines
DuoCut
Arpit's Page # 62
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.
RotoCut
Arpit's Page # 63
ROTOCUT
The ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller.
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.
Arpit's Page # 64
! 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
GasMultiburner Oven
Arpit's Page # 65
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).
Arpit's Page # 66
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
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.
Shortening
Arpit's Page # 68
Creaming
Layering
Flavor
Arpit's Page # 69
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.
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.
Arpit's Page # 70
9. HYDROGENATED VEGETABLE OIL :- (HVO)
Main function of HVO is to retain the moisture inside the
dough. Gives smoothness to the bite.
Arpit's Page # 71
PRODUCTION process of Biscuits
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
Arpit's Page # 72
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.
Arpit's Page # 73
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.
MIXING PROCESS :-
It has following characteristics which have been monitored
for better results
Arpit's Page # 74
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 :-
Arpit's Page # 75
RPM. Gauge roll speed has to be increased in every stand so as to
maintain the flow of sheets.
Arpit's Page # 76
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
Physical Changes
1. Formation of crust
2. Melting of fat.
3. Gas expansion in dough piece due to CO2
4. Water converted into steam
1. Heating Zone
2. Baking Zone
3. Coloring Zone
Chemical Changes
1. Gas formation
2. Starch gelatization
3. Protein changes
Arpit's Page # 7 7
4. Caramelisaion of sugar
5. Dexterisation
Arpit's Page # 78
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.
Arpit's Page # 79
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.
Arpit's Page # 80
function of packaging is protecting biscuit from foreign body
infestation, increasing shelf life, product and manufacturer into and
transportation.
Carton Boxes.
Display Boxes.
Bopp Items.
Wrapper.
Stickers.
Bopp Tapes.
Tear Tapes.
Shrink Films.
Polypropylene Sheets.
Pouches.
PVC Trays
Wax Papers.
Arpit's Page # 81
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.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
Availability Discounts
Arpit's Page # 82
Q.4 Which type of biscuits do you like to have(tick any
one)?
Wafers Cream
Cookies Plain
Week Month
Britannia Parle
Kellogg's Lancer
Yes No
Arpit's Page # 83
Please tell us something about yourself
Name :
Age(yrs) :
(10-15)
(15-20)
(20-25)
(25 & above)
Sex(M/F) :
Occupation :
Address :
Arpit's Page # 84
Questionnaire (Internal)
Yes No
27%
Yes
No
73%
17%
6-8 Hrs
46% 8-10 Hrs
10-12 Hrs
12 & Above Hrs
30%
Yes No
32%
Yes
No
68%
Yes No
Arpit's Page # 86
12%
Yes
No
88%
Yes No
17%
Yes
No
83%
Yes No
Arpit's Page # 87
33%
Yes
No
67%
Yes No
Partially Partially
Satisfied Unsatisfied
16%
31%
Yes
No
Partially Satisfied
Partially Unsatisfied
37%
16%
Arpit's Page # 88
Findings
Arpit's Page # 90
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.
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
! 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
Arpit's Page # 93
Page # 94