Hammad Hafeez Ahmad Raza: The Islamia University of Bahawalpur

PROCESSING AND PHYSICOCHEMICAL
ANALYSIS OF GROCERY & CONFECTIONERY

PRODUCTS AT
MITCHELL’S FRUIT FARMS LIMITED
RENALA KHURD, OKARA
By
Hammad Hafeez 2012-IU-603
Ahmad Raza 2012-IU-604
B.Sc (Hons) Agriculture
Department of Food Science & Technology

University College of Agriculture and Environmental
Sciences
The Islamia University of Bahawalpur
JUNE, 2016
PROCESSING AND PHYSICOCHEMICAL ANALYSIS OF FOOD PRODUCTS AT MITCHELL’S
Acknowledgement
All praises be to Allah who guides us in darkness and help in difficulties. If ocean
turn into ink and all of woods become pens even then the praises of Allah almighty
cannot be expressed. He, who created the universe and everything in the universe,
Nothing can happen without Allah permission and every one in universe is
answerable to him. Numerous blessing for Holy prophet (PBUH), who’s preaching
are right pathway for our success in the both lives.
My ineffable in deftness is due to Dr. Zulfiqar Ahmad (Assistant Professor)

Department of food science and technology, for his indelible patience to animate
my courage and providing all concern facilities magnificently.
This scholarly endeavor would have been futile without the cooperative attitude and
constructive minded and aluminous guidance of Dr. M uhammad Ammar Khan
(Lecturer) Department of food science and technology.
It is matter of great honor and pride for me to have the opportunity of internship in
the Mitchell’s fruit farms limited. I would like great gratitude for Mr. Shoaib Awan
(Production Manager) and Mr. Muhammad Idrees (Assistant Production Manager)
for their kind permission to complete my internship under their supervision.
Also special thanks to the Mitchell’s management and working staff for sincere
cooperation.
Last but not least, I feel pleasure to extend my heartfelt unlimited thanks to my
loving parents, dear brother and sisters for their moral and financial support and
countless prayers for my success.
Hammad Hafeez
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Dedication
3
4
Table of Contents
1 INTRODUCTION 8
1.1 History of Mitchell’s fruit farms limited 8
1.2 Aim: 9
1.3 Vision: 9
1.4 Mission 9
1.5 Quality Policy 9
1.6 HACCP policy 10
1.7 GMP policy 10
1.8 ISO-9001 Certification 10
2 DEPARTMENTS AND ADMINISTRATION 11
2.1 Departments in Mitchell’s fruit farms ltd. 11
2.2 Management 11
3 MITCHELL’S PRODUCTS 12
3.1 Grocery products 12
3.2 Confectionary products 13
3.3 New Products 13
4 FACTORY TOUR 20
4.1 Sections 20
4.2 Important Machine Working in Processing Plant At MITCHELL’S 23
5 PRODUCTION DEPARTMENT 24
5.1 Grocery Section 24

5.1.1 Jaam-e-Hayat 24
5.1.2 Chili Garlic Sauce 25
5
5.1.3 Chickpea 27
5.1.4 Golden Mist Marmalade 29
5.1.5 Mixed Fruit Jam 32
5.1.6 Orange squash 34
5.1.7 Saag 36
5.1.8 Ginger Garlic paste 36
5.1.9 Ginger paste 37
5.1.10 Apple jelly 37
5.2 Confectionary Section 40

5.2.1 Soft candy (Milk chocolate Éclairs) 40
5.2.2 Fruit Bon Bon (Hard candy) Orange flavor 42
5.2.3 Fruit Bon Bon (Hard candy) Strawberry flavor 42
5.3 Moulding Plant 43

5.3.1 Compound Chocolate 43
5.3.2 Happy Heart 44
5.3.3 Jubilee 45
5.4 Pulping Plant 47

5.4.1 Mango pulp 47
5.4.2 Mango pulp (Aseptic Filling) 49
6 QUALITY ASSURANCE DEPARTMENT 51
6.1 Laboratories 51
2) Incubation Lab: 51
6.2 Main Lab Tests 52

6.2.1 Determination of brix: 52
6.2.2 Determination of titrable acidity: 52
6.2.3 Determination of viscosity: 53
6.2.4 Determination of particle size: 53
6.2.5 Water hardness test 54
6.2.6 Water chlorine test 54
7 MY SPECIAL TASKS 55
7.1.1 Downtimes 55
7.1.2 Boilers 57
7.1.3 Water treatment plant 58
7.1.4 Overall Equipment Effectiveness (OEE) 59
7.1.5 Syrup Section 60
7.1.6 Weekly Progress Reports 61
6
Abstract
Mitchell’s Fruit Farms is a public limited company. It focuses on the strategy of giving
consumers high quality products at low price. Mitchell’s follows focused differentiation. As their
target market is, all the people looking for quality products. The Production and Quality control
departments use different procedures for production and analysis of several products like jams,
ketchup, toffees, drinks and squashes. Sophisticated food processing machinery was installed and
additional products were added to a growing range of preserves, fruit, drinks, juices, canned
fruits, sauces and vinegar. I applied my theoretical knowledge into practical work. I learned how
to tackle with people in professional life.
During these eight weeks, I analyzed the work of Production department and Quality department.
I performed different analysis in production that is Filling Temperature Analysis of jams, jellies,
mango pulp and squashes. I also analyzed the temperature after cooling because it affects the
quality of the product during storage. I did work in Quality Control Department in which I
studied different quality parameters (pH, acidity, filling temperature, viscosity) of each product.
pH of Jam-e-Hayat, mixed fruit jam, chili garlic sauce and mango pulp was 72, 72, 45 and 17
respectively. Acidity of Jam-e-Hayat, mixed fruit jam and chili garlic sauce was 0.14, 0.64 and
2.5.
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1 INTRODUCTION
1.1 History of Mitchell’s fruit farms limited

Mitchell's fruit Farm Limited, was incorporated as a Joint stock Company in 1933 by
introducing fruit squashes under the brand name of Mitchell's" Kissan".
In 1947, as a result of emergence of Pakistan, Mitchell's lost three fourth of its market to India,
however the company readjusted and carved to a substantial niche in the new country. The
Mitchell's family sold majority of its shares to the Pakistani investor’s in 1957. Since then many
new chapters have been added to this story. Sophisticated food processing machinery was
installed and additional products were added to a growing range of preserves, fruit, drinks, juices,
canned fruits, sauces and vinegar.
In 1980 came the sweetest chapter of all with diversification on confectionery industry.
Soon Mitchell's confectionery products comprising toffee, eclairs, and hard candy and fruit
bonbon favor with nationwide.
In 1983 Mitchell's golden jubilee was celebrated with a fan fare and a chocolate bar,
appropriately named as "Jubilee” was launched to commemorate the event.
In the year of 1994 it was ISO certified. In 2001, Mitchell's launched moulded chocolate and
launched products like gift box of pralines, golden hearts and top milk was accepted by
consumer.
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1.2 Aim
It is aim at Mitchell's to provide you with healthy, innovative and best quality food that
will tempt your appetite at all times.
1.3 Vision
1) To be market leader in this industry by keeping in view the importance of healthy
hygienic nutrition food to customer for their delightness.
2) To be a company which optimally combines its people, technology, management systems
and market opportunities to achieve profitable growth while providing fair returns to its
shareholder.
1.4 Mission
1) To be a leader in the markets, we serve by providing quality products to our consumers
while learning from their feedback to set even higher standards.
2) To be a company that continuously enhances its period technological skills to remain
internationally competitive in this day and age of increasing challenges.
3) To be a company that attracts and retains competent peoples by creating a culture that
foster innovations, promotes individual growth and rewards initiative and performance.
4) To be a company which optimally combines its people, technology, management system
and market opportunities to achieve profitable growth while providing fair returns to
shareholders.
5) To be a company that endeavors to set the highest standards in corporate ethics.
1.5 Quality Policy

We, at Mitchell’s fruit farms ltd, aim to be a leader in market we serve by providing quality
products to our customers while learning from their feedback to set even higher standards.
Our goals are –
a) To be a company that continuously to superior technological skills to remain competitive
in national and international markets in this day age of increasing challenges.
b) To be a company that attracts and retains competent peoples by creating a culture that
foster innovations, promotes individual growth and rewards initiative and performance.
9
c) To be a company which optimally combines its people, technology, management system

and market opportunities to achieve profitable growth while providing fair returns to
shareholders.
d) To be a company that endeavors to set the highest standards in corporate ethics and
fulfills its social responsibility.
1.6 HACCP policy

Our consumer’s health and well being is of prime importance to us; that’s why we are in the
process of introducing HACCP- A systematic approach to control all kinds of hazards at critical
points during processing.
We do this to win and maintain consumers-confidence.
1.7 GMP policy

Mitchell’s is committed to manufacture safe and high quality products.
We ensure food safety by paying attention to the following:
1) The quality of our product and processing.
2) Effectiveness of our sanitation programs.
3) Hygiene practices of our employees.
1.8 ISO-9001 Certification

Mitchell’s, a name synonymous with quality, taste and trust for over 78 years, gained, in 1998,
another distinction: ISO 9001 certification. And at no better time, than the successful completion
of 78 years. It is a matter of immense pride and honor for the Company that Mitchell’s has
become the first food company in Pakistan to achieve this prestigious distinction. What makes it
more significant is the fact that ISO 9001 involves all steps in the manufacturing chain; starting
from designing and development of products to production, right up to distribution. Thus the
Company, guided by its professional management, makes every effort to ensure that the product
reaches the consumer’s table just as promised: farm-fresh and maintaining the highest levels of
quality.
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2 DEPARTMENTS AND ADMINISTRATION
2.1 Departments in Mitchell’s fruit farms ltd.

Following are departments in Mitchell’s Fruits Farms Limited:
1) Marketing department
2) Sales department
3) Commercial department
4) Accounts & Finance
5) Production department
6) Planning and storage department
7) Technical services department
8) Quality assurance department
9) Human resource department
10) Research & Development department
2.2 Management
Managing Director Mr. Mian Mohsin
General Manager Mr. M. Mujeeb
Factory Manager Mr. Shoaib Awan
Department HOD
Production Mr. Shoaib Awan
Engineering Mr. Iftikhar
Store Mr. M. Shokat
Sales Mr. Haji Habib
Purchase Mr. Nadeem
Security Mr. Farquleet Zafar
H.R. Department Mr. Shaikh Naveed
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3 MITCHELL’S PRODUCTS
With nine categories encompassing over 140 products, we are proud to present the Mitchell's
family - products to grace your dining table on the breakfast and dinner occasions as well as
products to appease your sweet tooth.
3.1
Total Products: 15 Total Products: 22
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Total Products: 2
3.2
3.3 New Products

1) Fruit Punch
Extending its existing product line of Fruit Drinks, Mitchell's has introduced an irresistible
combination of Fruits in a drink as Mitchell's Fruit Punch. So now you can enjoy the taste of not
only one but many fruits in a single drink.
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2) Fruitica Orange (Instant Drink)

Keeping in view the increasing demand of powdered drinks, Mitchell's has launched its powder
instant drinks range in 25gm Sachets. The ideal thirst quenchers will be available in Orange
flavour.
3) Fruitica Lime (Instant Drink)

Keeping in view the increasing demand of powdered drinks, Mitchell's has launched its powder
instant drinks range in 25gm Sachets. The ideal thirst quenchers will be available in Lime flavor
4) Yum! Ketchup Stand-up Pouch (500g)

Mitchell's has launched its existing Yum! Ketchup in 500g stand-up pouch for the convenience
and economy of its consumers
5) Top Milk Fruit & Nut

A superb combination of Fruit & Nuts with Milk Chocolate to indulge your sweet-tooth.
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6) Luxuree 30g
Enjoy a taste of the exotic tropical! Luxuree is a wonderful treat consisting of a pure, white
coconut core wrapped in rich, milky smooth chocolate.
7) Luxuree 8g
Enjoy a taste of the exotic tropical! Luxuree is a wonderful treat consisting of a pure, white
coconut core wrapped in rich, milky smooth chocolate.
8) Apple Jelly Junior

Mitchell's has launched its classic preserves in smaller packaging, i.e., 200g Jars, so that you can
enjoy more flavours in lower price.
9) Golden Mist Marmalade Junior

enjoy more flavors in lower price.
10) Strawberry Jam Junior

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11) Mixed Fruit Jam Junior

enjoy more flavours in lower price.
12) Mango Jam Junior

13) Golden Apple Jam Junior

14) Hot & Sweet Sauce

Neither too sweet nor too spicy, Mitchell's has introduced a delicious combination of Tomatoes
and Chilies with the name of Mitchell's Hot & Sweet Sauce.
16
15) Synthetic White Vinegar

In addition to its pure Fruit Vinegar, Mitchell's is also launching Synthetic White Vinegar, which
can be taken with soups and garnishing of salads. Moreover, it can be used from being a food
enhancer or condiment, to meat tenderizer and natural food preservative.
16) Yum! Ketchup Stand-up Pouch

Mitchell's has introduced a new variant of Ketchup with the name of "Mitchell's YUM! Ketchup".
The delicious ketchup will be an excellent treat for the consumers in economical price.
17) Lychee Fruit Drink

Mitchell's Fruit Drinks are made from real fruits picked from its own gardens that will refresh
your body and soul. Keeping in view the increasing demand of fruit drinks flavours, Mitchell's
has launched another refreshing flavour, Lychee Fruit Drink, in its respective category.
18) Jaam-e-Hayat
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Keeping in view the growing demand of Red Syrups, Mitchell's has launched New Red Syrup in
810ml and 1.5Litres Pet Bottles. Be ready to taste the refreshing experience.
19) Apple Fruit Drink

Mitchell's Fruit Drinks are made from real fruits picked from its own gardens that will refresh
your body and soul. Keeping in view the increasing demand of fruit drinks flavours, Mitchell's
has launched another refreshing flavour, Apple Fruit Drink, in its respective category.
20) Mango Hyderabadi Pickle

We can safely guarantee for the fact that no meal is complete without Mitchell's Pickles!
Hyderabadi Pickles are a delicate assortment of fruits and vegetables matured through natural
processes, and carefully selected spices, made in a truly traditional way and carrying an authentic
homemade flavor. New, mouth watering recipes are constantly being formulated to complement
the existing range.
21) Mixed Hyderabadi Pickle

We can safely guarantee for the fact that no meal is complete without Mitchell's Pickles!
Hyderabadi Pickles are a delicate assortment of fruits and vegetables matured through natural
processes, and carefully selected spices, made in a truly traditional way and carrying an authentic
homemade flavour. New, mouth watering recipes are constantly being formulated to complement
the existing range.
22) Anniversary
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To commemorate the company's Platinum Jubilee, we take great pride in the launch of
Anniversary - a delectable selection of chocolates especially created for the discerning consumer
- as our way of saying "Thank You" to our loyal clientele for their support and patronage
spanning three generations.
23) Spinach Puree

Spinach Puree is made from the freshest spinach leaves and packed in tin can. Open the can to
cook and prepare a delicious meal with either vegetables like Potatoes, or with meat. You just
need to add spices and oil to cook. It can be eaten with Bread, Paratha or Rice.
Spinach Puree is packed in 800gms cans for the pure convenience of consumers.
24) Super Milk Toffees
Mitchell's new Super Milk Toffees are bigger in size and better in taste than any other Milk
Toffees, which will bring lots of fun and excitement for you to share with your friends and
family.
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4 FACTORY TOUR
4.1 Sections
Publicity Board visible from Renala Khurd Bypass while

Aerial View of Mitchell's Factory
heading towards Lahore
Factory Offices Factory Offices
Conference Room Quality Control Lab
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Micro-biological Lab Chocolate Conching Machine
Molded Chocolate Plant Enrobed Chocolate Plant
Squashes & Drinks Filling Machine Sugar Confectionery Section
21
Precision Weighing Machine in Sugar

Toffee & Hard Candy Wrapping Machine
Confectionery Section
Sauces Filler Preserves Filler
2 Views of Groceries Section
Can Retort Automatic Can Seamer
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4.2 Important Machine Working in Processing Plant At MITCHELL’S

Machine Company Country Product
Pasteurizer NKR engineering (Pvt) ltd Syrup
Thermo break Ing. A. Rossi Italy Pulp
Candy blower HANSELLA Candy
Candy Rope Former BOSCH Germany Candy
Trans wraps machine BOSCH Nederland Jar labels
Pouch making & filling BOSSAR Spain Ketchup
Shrink wrap machine Smipack Jars, Bottles
Glass bottle Labeling LANGGUTH Bottles
10g/100g pouches Sama Engineering Pakistan Ketchups
Stephan mixer Stephan machinery Germany Pastes
Blancher JIAHAO technology company ltd. China Saag, Chickpea
Can Retort STERINOV France Saag, Chickpea
Glass jar filling Cft packaging Jams, Jellies
Evaporator Ing. A. Rossi Pulp
PET conveyors & labeling Esleeve Sauces
Wrapping machine (jars) Portovantovano MN Italy Jams, Jellies
Coding Machines Domino A400& A220 All products
Candy twist wrap (old) Nageema Germany Candies
Candy twist wrap (new) P.M Italy Candies
Gas Boilers Heavy Mechanical complex ltd. Pakistan ---
PET filling machine Zilli& Bellini Sauces
Lab Equipments Parameter
Hardness test kit MERCK Germany Water Hardness
Chlorine testing kit HANNA instruments Rumania Chlorine
Hardness testing kit HANNA instruments Rumania Hardness
Viscometer Brookfield Viscosity
TDS meter MARTINI instruments TDS
pH meter HANNA instruments Rumania pH
Weighing balance Accurate scale system Weight
Moisture analyzer Sartorius % moisture
Refractometer HANNA instruments Rumania Brix
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5 PRODUCTION DEPARTMENT
5.1 Grocery Section
5.1.1 Jaam-e-Hayat
Ingredients
Sugar, glucose syrup, citric acid, sodium benzoate, polysucralose, Natural
Extracts; Rose, ushna, aniseed, kewra, color.
Procedure
1) Issue all the ingredients required for Jaam-e-Hayat from grocery and confectionary
store.
2) Take sugar and make sugar syrup of 80 brix.
3) Store Sugar syrup Into a storage tank for a specific time .
4) Transfer the syrup to a mixing tank and all natural extracts add to it.
5) Heat the syrup for a specific time then send it to filler.
6) PET bottles washed by a pressurized water spray in washer.
7) Fill the bottles with Product through the filler at 60˚C filling temperature.
8) After filling, Capper put the caps on the bottles and sealed them.
9) Cooling took place in cooling tunnel.
10) Progressively , Labeling, Coding and secondary packaging occurred.
Quality Standards
˚Brix 72
Acidity% 0.14
Quality Analysis (Jam-e-hayat)

Date Parameters F1 F2 F3 F4 F5 F6 Average
Brix 72 72 71 72 71 72 71.67±0.52
24/6/2015
Acidity 0.16 0.14 0.15 0.14 0.13 0.14 0.14±0.01
Brix 72 72 71 72 71 72 71.67±0.52
27/6/2015
Acidity 0.14 0.16 0.14 0.14 0.14 0.14 0.14±0.01
Brix 72 71 72 72 71 72 71.67±0.52
11/7/2015
Acidity 0.15 0.14 0.15 0.14 0.14 0.14 0.14±0.01
Brix 72 72 72 72 71 72 71.83±0.41
17/7/2015
Acidity 0.14 0.15 0.16 0.14 0.14 0.15 0.15±0.01
Brix 71 72 71 72 72 72 71.67±0.52
22/7/2015
Acidity 0.17 0.16 0.15 0.14 0.14 0.15 0.15±0.01
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5.1.2 Chili Garlic Sauce

Ingredients
Vinegar, Vitamin C, Red Chili powder, Salt, Sodium benzoate, Sugar, Thick flow Powder,
Tomato concentrate, Garlic powder, Xanthin gum, Color.
Procedure
1) Issue all the ingredients required for Chilli Garlic Sauce from grocery and
confectionary store.
2) Make a mixture sodium benzoate, Xanthin gum, vitamin C and add it into water in
chemical mixer at above 90˚ C for 20-25 minutes.
3) Prepare sugar syrup in syrup room and add other ingredients into it and transfer to
vacuum pan.
4) Add chemical mixture into a vacuum pan after required ˚Brix is obtained.
5) Transfer the product to Bossar Machine’s filler and automatically fill the pouches.
6) After filling, top sealing, cooling, drying and secondary packaging has been
performed.
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Quality Standards
˚Brix 45
Acidity% 2.5
Viscosity (cps) 2500
Quality Analysis (Chili Garlic Sauce)

Brix 45 45 45 46 45 46 45.33±0.52
6/7/2015 Acidity 2.54 2.5 2.55 2.55 2.49 2.54 2.53±0.03
Viscosity 2550 2490 2470 2465 2500 2500 2495.83±30.40
Brix 45 45 45 45 45 45 45.00±0.00
8/7/2015 Acidity 2.4 2.49 2.52 2.55 2.53 2.56 2.51±0.06
Viscosity 2520 2510 2510 2520 2525 2550 2522.50±14.75
Brix 45 46 45 46 45 46 45.50±0.55
13/7/2015 Acidity 2.54 2.49 2.47 2.44 2.57 2.52 2.51±0.05
Viscosity 2490 2490 2490 2470 2540 2590 2511.67±44.91
Brix 45 45 45 46 45 45 45.17±0.41
17/7/2015 Acidity 2.44 2.46 2.54 2.54 2.56 2.53 2.51±0.05
Viscosity 2505 2510 2510 2510 2530 2510 2512.50±8.80
Brix 45 45 45 46 45 45 45.17±0.41
2/8/2015 Acidity 2.55 2.54 2.53 2.45 2.44 2.47 2.50±0.05
Viscosity 2510 2505 2490 2490 2510 2520 2504.17±12.01
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Flow Diagram
5.1.3 Chickpea
Ingredients:
Water, Salt, Chickpea
Procedure:
1) Issue chickpeas from grocery store.
2) Chickpeas soak in water tank for at least 4 hours.
3) After which these are put into Blancher which is working at 100˚C and completes one
turn in about 25 minutes.
4) Blanched chickpeas are weighed and fill in cans manually.
5) Then brine solution of 2-3 ˚Brix is filled by filler in remaining space.
6) Filled cans are passed through a closed conveyer which provides heat of 100˚C by hot
air.
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7) Tops are sealed by sealing machine before in-pack sterilization.
Retort Functioning
Venting 66-100˚C 3 minutes
Heating 109-126˚C 8 minutes
Sterilization 126˚C 15 minutes
Precooling 100-90˚C 6 minutes
Cooling 70-30˚C 35 minutes
Flow Diagram
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5.1.4 Golden Mist Marmalade

Ingredients
Orange concentrate, Vitamin C, Citric Acid, Pectin, Sugar, Sodium Citrate, Orange
flavor, Grape Fruit Juice, Orange Shred.
Procedure
1) Issue all the ingredients required for GMM from grocery and confectionary store.
2) Take 120 kg shredded orange peel and blanch it.
3) Take 1200 kg Sugar and make the sugar syrup of 80˚Brix.
4) Take 40 kg Grape fruit juice and 10 kg orange concentrate.
5) Dilute the grape fruit juice with water and achieve a 2-3˚Brix and give the stay time of
one day which results in settle down of fiber and other coarse material.
6) Cleared floating juice is separated out and mix with the sugar syrup.
7) Make a mixture of sodium citrate, pectin and vitamin C and add it into water in
chemical mixer at 90˚C for 25- 30 minutes.
8) Add syrup with shred in vacuum pan and create the vacuum 600 mmHg and set the
temperature at 100˚C.
9) When we achieve 75-76˚Brix, stop heating and add chemical mixture, color, flavor
and citric acid.
10) Start heating again and create vacuum.
11) After completion of process, pour the product into storage tank until all entire product
consumed on the filler.
12) Fill the glass jars with product at 80˚C of filling temperature.
13) Progressively, capping, inspection, cooling, labeling, coding and secondary
packaging (shrink wrap) has been performed.
14) Then final product stored in go down.
Workers on line and their Placement

Placement Number of Workers
Chemical room 02
Sugar syrup preparation 03
Juice feeders 03
29
Cooking 04
Jar feeders 04
Filler 01
Capper 01
Inspection 02
Labeling 02
Label checker 01
Printer 01
Secondary packaging 06
Juice transfer 01
Total workers 31
Quality Standards
˚Brix 72
Acidity% 0.65
Filling Temperature 75
Quality Analysis
Brix 72 72 71 71 72 72 71.67±0.52
25/6/2015 Acidity 0.65 0.61 0.62 0.65 0.64 0.64 0.64±0.02
Filling Temp. 75 76 76 79 77 76 76.50±1.38
Brix 71 72 71 72 71 72 71.50±0.55
29/6/2015 Acidity 0.65 0.61 0.62 0.63 0.64 0.64 0.63±0.01
Filling Temp. 76 76 75 74 76 76 75.50±0.84
Brix 72 71 72 72 71 72 71.67±0.52
7/7/2015 Acidity 0.65 0.64 0.63 0.66 0.62 0.64 0.64±0.01
Filling Temp. 72 76 74 75 75 76 74.67±1.51
Brix 72 72 72 72 71 72 71.83±0.41
15/7/2015 Acidity 0.64 0.63 0.63 0.56 0.62 0.64 0.62±0.03
Filling Temp. 75 76 75 75 75 76 75.33±0.52
Brix 72 72 71 72 72 72 71.83±0.41
19/7/2015 Acidity 0.65 0.64 0.63 0.66 0.62 0.64 0.64±0.01
Filling Temp. 75 76 74 74 74 76 74.83±0.98
30
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5.1.5 Mixed Fruit Jam

Ingredients
Sugar, Apple Pulp, Mango Juice Pulp (With Chemical), Mango Juice Pulp (AC),
Orange Concentrate, Citric Acid, Pectin, Sodium Benzoate, Vitamin C.
Procedure
1. Issue all the ingredients required for mixed fruit jam from grocery and confectionary
store.
2. Take the Raw apple, mango and orange.
3. Wash them and make pulp through the pulper.
4. Take sugar and make sugar syrup of 80 ˚Brix.
5. Mix fruit pulp with sugar syrup.
6. Make a mixture of sodium benzoate ,pectin , vitamin C and add it into a water in
chemical mixer at above 90 ˚C for 20-25 minutes.
7. Transfer the syrup into the vacuum pan and create the vacuum of 600 bars and set the
temperature at 100 ˚C for 45 minutes.
8. When we achieve our required brix add chemical mixture and citric acid.
9. After completion of cooking, transfer the product into the storage tank.
10. Fill jar with product through the filler at 80 ˚C of filling temperature.
11. Progressively, capping, inspection, cooling, labeling, coding, and secondary
packaging (Shrink wrap) has been Performed.
12. Then final product stored in go down.
Workers and Their Placement

Point No. of workers
Juice feeding 03
Syrup Preparation 03
Syrup Juice Mixing 01
Chemical Mixer 02
Vacuum Pan 04
Jar Feeder 04
Filler 01
32
Capper 01
Screening 03
Labeling 02
Label Checker 02
Printer 01
Secondary packing 07
Total Workers 33
Quality Standards
Brix 72
Acidity 0.64
33
5.1.6 Orange squash

Ingredients
Citrus pulp, Sugar, Citric acid, Carboxy methyl cellulose (CMC), Potassium meta bisulphate
(KMS), Salt
Procedure
The juice is shifted in juice mixing tank, mix CMC and salt in hot water. Add this
mixture to the juice and mixing is done. This juice is pumped to sugar mixing room in which two
stainless steel tanks are mixing. Then sugar is added in the juice while continually mixing the
tank. Add KMS and citric acid in the juice. Mix all the ingredients till 40 Brix. Then this mixture
is passed through a pulper which separates all the solid materials from squash. This pulper is
equipped with a very fine sieve having mesh size less than 10. Squash is passed through
Homogenizer that homogenizes the mixture completely. Then it is transferred to the filler where
it is filled in PET bottles, capping and washing of bottles is done then after labeling and coding
bottles are packed in cartoons and stored in finish goods store from where product in marketed.
Quality Standards
Brix 40
Acidity 1.65
Quality Analysis
Brix 41 41 40 41 40 40 40.50±0.55
9/7/2015
Acidity 1.65 1.63 1.63 1.66 1.59 1.63 1.63±0.02
Brix 42 41 41 40 42 40 41.00±0.89
10/7/2015
Acidity 1.66 1.65 1.65 1.64 1.66 1.65 1.65±0.01
Brix 40 40 41 40 40 41 40.33±0.52
25/7/2015
Acidity 1.66 1.65 1.65 1.65 1.66 1.65 1.65±0.01
Brix 39 40 41 40 40 40 40.00±0.63
3/8/2015
Acidity 1.65 1.65 1.65 1.66 1.65 1.67 1.66±0.01
Brix 40 40 41 40 40 40 40.17±0.41
10/8/2015
Acidity 1.67 1.67 1.66 1.65 1.65 1.65 1.66±0.01
34
Flow Diagram
35
5.1.7 Saag
Ingredients
Saag, Spinach, Green pepper, Corn flour, Salt
Procedure
1) Take 80 kg saag and 20 kg spinach, wash it combine and cut with cutter machines.
2) Blanch it at 100˚C for 25 minutes in blancher.
3) Add green pepper, corn flour and salt in Stephan mixer and grind it.
4) Pour the processed material into a storage tank and provide steam within it to avoid
heat loss and fouling problem during filling.
5) Material transfer to the filler from storage tank and fill the cans at filling temperature
75˚C and speed of 67 cpm.
6) After filling of cans, upper seal of can is inserted by steam pressure which seals them
through a seamer.
7) Then cans are filled into iron pallets to insert them into a Retort. In retort following
operations occur.
8) Sterilized cans then stored for labeling when required.
Retort Functioning
Venting 66-100˚C 3 minutes
Heating 109-126˚C 8 minutes
Sterilization 126˚C 65 minutes
Precooling 100-90˚C 12 minutes
Cooling 70-30˚C 40 minutes
5.1.8 Ginger Garlic paste

Ingredients
Ginger, Garlic, Vegetable oil, Modified starch, Acetic acid, Salt, Potassium Met bisulphate,
sodium benzoate, Vitamin C, Water.
Procedure
1) Take all the ingredients from the grocery store.
2) Put all the ingredients into Stephan mixer and close the pan.
36
3) Mix the ingredients at 80˚C and create a vacuum of 700 mbar and running time of
machine is 13 minutes.
4) The final product should have 11˚Brix.
5) After that, Paste transfer to the preserve line where filling process is done.
6) Progressively, filling, capping, precooling, cooling, inspection, drying, coding, labeling
and secondary packaging occurred.
5.1.9 Ginger paste

Ingredients:
Ginger, Vegetable oil, Modified starch, Acetic acid, Salt, Potassium Met bisulphate, sodium
benzoate, Vitamin C.
Procedure:
1) Take all the ingredients from the grocery store.
2) Put all the ingredients into Stephan mixer (150kg) and close the pan.
3) Mix the ingredients at 90˚C and create a vacuum of 700 mbar and running time of
machine is 07 minutes.
4) The ˚Brix of final product should be 8.
5) After that, Paste transfer to the preserve line where filling process is done.
6) Progressively, filling, capping, precooling, cooling, inspection, drying, coding, labeling
and secondary packaging occurred.
5.1.10 Apple jelly
Ingredients:
Vitamin C, Citric Acid, Pectin, Sugar, Allura red (Color), Apple flavor, Apple pulp,
Sunset yellow (color)
Procedure:
1) Issue all the ingredients required for Apple jelly from grocery and confectionary store.
2) Take Sugar and make the sugar syrup of 80˚Brix.
3) Take apple pulp and dilute it with water and achieve a 2-3˚Brix and give the stay time of
one day which results in settle down of fiber and other coarse material.
37
4) Cleared floating juice is separated out and mix with the sugar syrup.
5) Make a mixture of, pectin and vitamin C and add it into water in chemical mixer at 90˚C
for 25- 30 minutes.
6) Add syrup in vacuum pan and create the vacuum 600 mmHg and set the temperature at
100˚C.
7) When we achieve 72˚Brix, stop heating and add chemical mixture, color, flavor and citric
acid.
8) Start heating again and create vacuum.
9) After completion of process, pour the product into storage tank until all entire product
consumed on the filler.
10) Fill the glass jars with product at 85˚C of filling temperature.
11) Progressively, capping, inspection, cooling, labeling, coding and secondary packaging
(shrink wrap) has been performed.
12) Then final product stored in go down.
38
39
5.2 Confectionary Section
5.2.1 Soft candy (Milk chocolate Éclairs)

Ingredients:
SMP, water, starch powder, glucose, sugar, lecithin, salt, butter flavor, caramel, caramel color,
condensed milk flavor, vanillin, calcium, coconut oil, chocolate, butter cream flavor.
Procedure:
1) Take milk, water, salt and starch powder and prepare it in a pan.
2) Take fat and lecithin and make a mixture by heating with steam.
3) Sugar is inserted into sugar tank and glucose in a glucose storage tank.
4) All above ingredients (Point 1-3) combines in a mixing and heating chamber.
5) From where it is transferred to a storage vessel in which continuous agitation occur.
6) Then this whole material cooked in a cooker at 116˚C for 30-35 minutes.
7) Cooked material poured on water cooled plates (cooking oil and starch powder used as
propellants) where it gains required consistency.
8) Material divides in bulk parts which can easily inserted into Batch Former (a machine).
9) Batch former shifted the shape of material into lower diameter by its rollers and transfer
the material to Rope Former.
10) A chocolate pump inserts the chocolate into batch through a pipe.
11) Rope former convert the shape into a rope at 4 stages. Every stage thickens the rope and
last couple of disk gives our required size.
12) Next process is cutting by a cutter or dye.
13) Blower blows the cool air on a 2 storey conveyor on which cut ropes are spread.
14) Twist wrapping is done in wrapping machines. Average speed of wrapping is 500 candies
/ minute.
15) In secondary packaging, every pouch contains 43 candies and every carton contains 36
pouches.
Check list for Soft Candy
Cooking temperature 116˚C
Unit weight 3.2 g
Chocolate filling Ok
Wrapping quality Ok
40
Seal Ok
Coding Ok
Number of candy /pouch 43
Line CIP Ok
Hygienic conditions Ok
Area Temperature 24.5˚C
Area humidity 36%
Flow Diagram
41
5.2.2 Fruit Bon Bon (Hard candy) Orange flavor

Ingredients:
Sugar, Glucose, Citric Acid, Orange oil, Color mix, Apple jam
Detail:
We worked on Fruit Bon Bon processing line and observe the whole procedure of hard candy
manufacturing.
Its start from the mixing of sugar and glucose which is heated at 142˚C for 4 minutes after which
it acquires strength of hard candy which is inserted into a flavor mixer and all the chemicals
including color and flavors are added thoroughly.
Then prepared material put on the cooled plates and then inserted into batch former.
A fruit jam is filled into the material by a filling pipe which takes the jam from a drum by the
force of a feed pump.
Batch former push the material into rope former after which it cuts into required length of toffee
and passed through a blower which cool it down make it hard.
Wrapping and secondary packaging is done afterwards.
5.2.3 Fruit Bon Bon (Hard candy) Strawberry flavor

Ingredients:
Sugar, Glucose, Citric Acid, Strawberry flavor, Color mix, Apple jam
Detail:
Today we worked on Fruit Bon Bon processing line and observe the whole procedure of hard
candy manufacturing.
Its start from the mixing of sugar and glucose which is heated at 142˚C for 4 minutes after which
it acquires strength of hard candy which is inserted into a flavor mixer and all the chemicals
including color and flavors are added thoroughly.
Then prepared material put on the cooled plates and then inserted into batch former.
A fruit jam is filled into the material by a filling pipe which takes the jam from a drum by the
force of a feed pump.
Batch former push the material into rope former after which it cuts into required length of toffee
and passed through a blower which cool it down make it hard.
Wrapping and secondary packaging is done afterwards.
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5.3 Moulding Plant
5.3.1 Compound Chocolate

Ingredients:
Sugar, Vegetable fat, Skimmed milk powder, Cocoa Powder, Lecithin, Artificial flavor
Procedure:
1) Issue all the ingredients from grocery & Confectionary store.
2) Take sugar, vegetable fat, SMP and cocoa powder in mixer and mix it at 45˚C for 15 -20
minutes which will give a product particle size of 45 µ. Its capacity is 450 kg.
3) Transfer the material to the refiner which has 5 rollers which has different temperature
and converts the particle size to 24 µ.Its capacity is 150 kg.
4) Then material tends to the conch which mix it for 8 hours regularly during which
Artificial flavor, lecithin and remaining fat is added. Its capacity is 6 tones.
5) After that process, product is transferred to storage tank which is double injected and hot
water circulates into it until the chocolate is consumed.
Quality Standards
Viscosity (cps) 5000
Particle size (µ) 24
Quality Analysis (Chocolate)

Viscosity 4945 4900 5000 5050 5037 4760 4948.67±108.34
24/6/2015
Particle size 24 24 24 24 23 24 23.83±0.41
Viscosity 5035 5120 5040 5100 5000 5040 5055.83±44.99
27/6/2015
Particle size 23 23 24 24 24 24 23.67±0.52
Viscosity 4900 5240 4990 5000 4990 5020 5023.33±113.96
11/7/2015
Particle size 23 24 22 25 24 23 23.50±1.05
Viscosity 4790 4760 4700 4970 4905 4990 4852.50±119.32
17/7/2015
Particle size 24 23 24 24 23 24 23.67±0.52
Viscosity 4917 4990 5000 5090 4970 5005 4995.33±56.36
22/7/2015
Particle size 24 24 23 25 23 24 23.83±0.75
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5.3.2 Happy Heart

All pure chocolate products are manufactured in molding plant.
Ingredients:
Compound Chocolate, Rice crispy
Procedure:
Whole procedure and manufacturing line of happy Heart is mentioned below
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5.3.3 Jubilee
Ingredients Composition
Nougatine Hyfoama Versa whip*
Salt
Ground Sugar
Water
Fat mix Cocoa powder
Skimmed milk powder
Socfat**
Syrup Sugar
Glucose
Water
Caramel Glucose, milk powder, water, salt, sugar, socfat, calcium,
lecithin,
Chocolate SMP, CBS***, sugar, cocoa powder, lecithin, vanillin****,
condensed milk flavor, butter flavor, chocolate cream flavor
*hydrolysed soy proteins (combined vegetable proteins) which expand at specific temperature.
** Socfat trans free shortening is a palm based blended fat specially texturized to impart plasticity and
smooth consistency that facilitate mixing and ease of us at ambient temperatures.
***cocoa butter substitute.
**** Vanillin is a phenolic aldehyde
Procedure:
1) Take ingredients for Nougatine preparation from grocery and confectionary store.
2) Prepare hyfoama by mixing versa whip, salt, sugar and water in defined quantities and
heat them at 79˚C (Company standards = 80˚C)
3) Prepare fat mix by mixing cocoa powder, skimmed milk powder and socfat at same
conditions as hyfoama.
4) Prepare syrup by mixing (180 minutes) water with glucose and sugar at same conditions.
5) Combine all three recipe in a mixing tank and product is called Nougatine .
6) Take ingredients for caramel and prepare caramel by cooking at 113˚C for 30-35 minutes.
7) Prepare Compound chocolate by mixing all ingredients in chocolate room.
8) Transfer nougatine and caramel to their specific feeders at conbar machine.
9) Lower layer is of nougatine and upper layer is caramel and both will combine and pass
through first cooling tunnel.
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10) After this dividers divide this material into layers of our required width.
11) Cutters will cut the layers into small pieces of specified length.
12) Chocolate enrobers provide the coating of chocolate to the product then coated conbar
will pass through second cooling tunnel.
13) Product is ready to pack on wrap machine.
Jubilee Flow Diagram
46
5.4 Pulping Plant
5.4.1 Mango pulp

Ingredients:-
Mangoes, Citric acid, Ascorbic acid, Sodium Meta bisulphate
Procedure:-
1) Take fresh raw mangoes from the garden and put on the conveyor where sorting is
performed manually by workers.
2) Graded mangoes move on elevator conveyor and drop into a washing conveyor.
3) After washing with cold water, transfer the mangoes to the sorting conveyor (691 rpm)
where rollers of about 3 inches in diameter rotate the mangoes and facilitate the workers
to pick up the undesirable mangoes.
4) Next is the brush conveyor contains a series of brushes, rotates, wash and remove the
dust at a time.
5) Now our cleaned mangoes are ready for processing in destoners (which operate at 85˚C)
which removes all the mango stones and maximum peel.
6) The raw pulp goes into a tank from where it moves to hot break (A heat exchanger)
works at 95˚C.
7) Then Pulp moves to the pulper (working speed 80%, mesh 1.25mm, 1885 rpm) which
homogenize the material and next moves to refiner.
8) Pulp refiner (mesh0.8mm) removes all the fiber and remaining peel particles.
9) Refined pulp store in a storage tank which has the capacity of about 3000 liters.
10) When storage tank completely fill, juice transfers to the pasteurizer by passing through
the filters (0.05mm).
11) After pasteurization at 90˚C juice is stored in a mixing tank where chemicals are mixed to
preserve the mango juice for direct use or manufacturing of other products like jams.
47
48
5.4.2 Mango pulp (Aseptic Filling)

Ingredients:-
Mangoes, Citric acid, Ascorbic acid,
Procedure:-
1) Take fresh raw mangoes from the garden and put on the conveyor where sorting is
performed manually by workers.
2) Graded mangoes move on elevator conveyor and drop into a washing conveyor.
3) After washing with cold water, transfer the mangoes to the sorting conveyor (691 rpm)
where rollers of about 3 inches in diameter rotate the mangoes and facilitate the workers
to pick up the undesirable mangoes.
4) Next is the brush conveyor contains a series of brushes, rotates, wash and remove the
dust at a time.
5) Now our cleaned mangoes are ready for processing in destoners (which operate at 85˚C)
which removes all the mango stones and maximum peel by providing steam.
6) The raw pulp goes into a tank from where it moves to Thermal break (A heat exchanger)
works at 95˚C .The function of thermal break is to soft the pulp.
7) Then Pulp moves to the pulper (working speed 80%, mesh 1.25mm, 1885 rpm) which
homogenize the material and next moves to refiner.
8) Pulp refiner (mesh0.8mm) removes all the fiber and remaining peel particles.
9) After that refined pulp moves to filter and at this stage ˚Brix of product is approximately
20.
10) Pulp moves to Evaporation plant which consists of two effect evaporator system.
11) Pulp firstly enter into 2nd effect evaporator where it circulates and moves to first effect
evaporator by first circulating pump where steam is provided to heat the pulp at 65˚C.
12) Vapors of first effect evaporator moves to the second effect evaporator which is the
source of heat in 2nd effect evaporator.
13) Remaining vapors moves to the condenser where cold water turns them into liquid state
and tends to the cooling tower.
14) After achieving 28˚Brix of the pulp, it moves to the deareator, then to the homogenizer
(19 bars).
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15) After homogenization, pulp moves to the sterilizer where sterilization takes place for 40
minutes at 110˚C.
16) Product is suddenly cooled by chilled water (10˚C) which cools down the product at 35˚C.
17) Now product is ready to fill the pouches under Aseptic conditions and moves to the filler
and fills the pouches aseptically.
18) Finally pouches are placed into drums which are stored for a long while.
Flow Diagram
50
6 QUALITY ASSURANCE DEPARTMENT
6.1 Laboratories
There are 5 labs which are as follows
1) Main lab
2) R& D lab
3) Incubation lab
4) Microbiology lab
5) Line control lab
1) Main Lab:
All the incoming raw materials are tested for their predefined Mitchell’s quality
standards. If the incoming raw material full fills the quality requirements then the product is
passed if not then the product is failed and returned to supplier as no compromise on quality
inputs. Viscosity of products, pH & TDS of boiler water are tested and a daily report is sent to
the Boiler Engineer. pH, Acidity of jams and jellies. Moisture %age. Particle size is tested. Li,
Na & K is tested in ppm with the help of flame photometer. FCMP is tested in main lab and
incoming glucose is tested in the main lab Vacuum testing of the canned products is tested in the
main lab.
2) Incubation Lab:
Samples are taken from the line from production section and these samples as one
sample per batch is tested and kept in the incubation lab chronically for two years and studied for
their behavior in storage. If any complain comes from market about product then the product that
comes from market is compared for its quality with the reference sample from the incubation lab
of the same batch code.
3) Line Control Lab:
This is very critical lab for checking the online production in the grocery hall for
its best defined quality. The instrument that is used in the lab is calibrated according to the ISO
standards. The titratable acidity, Brix and filling temperature of the product is noted if it matches
with the predefined standards then well and good if not then the production supervisor is given
the suitable suggestions to adjust the acidity , Brix and filling temperature.
51
4) R& D Lab:
The products that are prepared by the R & D section are evaluated by the sensory
evaluation panel in the sensory evaluation lab and a Performa is given to the panelists and a blind
evaluation is done and their observations are recorded in the sensory evaluation Performa and
submitted to QAM.
5) Microbiology Lab:
Microorganisms’ plays very important role not only deteriorates the products but
also create health hazardous. Microbial testing is carried out to determine safety of workers,
products and process and working environment. Moreover water and Air microbial load is also
checked on monthly basis. All microbiology tests are carried out in micro lab.
6.2 Main Lab Tests
6.2.1 Determination of Brix:

Objective: To determine the amount of total soluble solids in products.
Scope: Jam, Jellies, Marmalades, Sauces, Juices, Squashes, Drinks, Pulps, Ketchup etc.
Apparatus: Refractometer, Light source (Lamp), and Distilled water (for calibration)
Procedure:
1) Calibrate the Refractometer it should show “Zero” reading of distilled water at 20 C.
2) Apply the thin layer of product on Refractometer slide.
3) Observe reading through lens by adjusting the shade with help of knob.
4) Note reading %. Clean the Refractometer slide with water.
6.2.2 Determination of titrable acidity:

Objective: To determine the Acidity of Products either as citric acid, acetic acid or lactic acid.
Scope: Almost all grocery products
Reagents: 1 % Phenolphthalein, 0 .1 N NaOH
Procedure:
1) Take sample in conical flask
2) Add some water for uniform stirring
3) Add 3-4 drops of phenolphthalein
4) Titillate against 0.1 N NaOH
52
5) Light pink color is end point

6) Stop titration & note the reading
Calculation:
For Citric Acid = ml of (0.1 N) NaOH used X 0.64

Weight of sample
For Acetic Acid = ml of (0.1N) NaOH used X 0.60

Weight of sample
For Lactic Acid = ml of (0.1N) NaOH used X 0.009
Weight of sample
6.2.3 Determination of viscosity:

Viscosity: It is the resistance to flow
Scope: Sauces, Melted chocolate, Syrup, chutneys, pasts etc.
Apparatus: Brookfield Viscometer
Procedure:
1) Dip the specific number spindle in the sample
2) Turn on the viscometer by adjusting its speed. Speed in rpm.
3) Reading is taken by pushing the speed button & power button simultaneously.
4) Hold the speed button until reading is taken.
5) Spindle & Speed in rpm, specify a factor “f” and dial reading is “d” is noted. Viscosity is
calculated as
F x d = Viscosity in centipoises
Precaution: Viscosity should be checked at 50 C.
Chocolate viscosity stander = 7000 + 1000 cps
6.2.4 Determination of particle size:

Objective: To determine the particle size of products e.g. chocolate.
Scope: Chocolate & all other products in which particle size maintenance are necessary
to improve the texture & uniformity.
53
Apparatus: Elcometer or Micrometer

Procedure:
1) For calibration, rotate its screw until it touches to the opposite side.
2) At this point reading on the screw.
3) Slowly move the cylinder until both parts touch each other.
4) Note reading, it’s in mm. Convert it in microns for chocolate.
Chocolate particles size sander = 25 um
Precaution: Before particles size determination cleans the micrometer properly.
6.2.5 Water hardness test

Object: To determine Hardness of water
Scope: Boiler water, Treated water, Waste water, Feed water
Apparatus: Hardness Kit
Procedure:
1) Take 5ml sample of water to be test.
2) Add 3 drops of H-1 solution which convert its color to bright red.
3) Add H-2 solution drop by drop and stir the sample continuously.
4) Red color converts to greenish color it will be its end point.
5) Note the reading on the dropper that how much H2 solution is used.
6) This value will be Hardness of Water
6.2.6 Water chlorine test

Object: To determine Residual chlorine in water
Scope: Boiler water, Treated water, Waste water, Feed water
Apparatus: Chlorine Kit
Procedure:
1) A chlorine kit consists of two parts in which one part contain standard color and values
and second one in which we take sample.
2) Take 5ml sample of water in chlorine kit.
3) Add 3 drops of NaOH reagents And 5 drops of H2SO4 reagents.
4) These reagents will change the color of water which resemble one of the standard color
and that is the value of chlorine in water.
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7 MY SPECIAL TASKS
7.1.1 Downtimes
The time during in which a machine is out of action or unavailable for use is called downtime.
Purpose
To calculate our real total production in comparison with ideal production.
Types
According to Mitchell’s standards there are two types of Downtimes.
1) Major downtimes; Stoppage of more than 10 minutes
2) Minor downtimes; Stoppage of less than 10 minutes or 10 minutes
Further downtimes are classified technically as
1) Electrical stoppages
2) Mechanical stoppages
3) Utility stoppages
4) Supply chain stoppages
Working
1) We worked on processing lines to calculate all minor and major stoppages.
2) Sum up all minor and major, electrical, mechanical and utility stoppages.
3) Subtract the sum of all the stoppage times from total processing time.
4) For example, we have a total of 480 minutes in one shift and our production rate is 120
jars/minutes, so if we calculate our ideal production, it will be 480 x120.
5) If there is a break of 30minutes then remaining working time is 450 minutes, so now is
the need to subtract the downtimes, in this way we calculate during processing of
complete shift.
6) If we calculated the downtimes of 70 minutes then our remaining working time is 450-70.
7) Now our production will be (450-70) x120.
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Actual
Mixed Fruit Jam (450 g)

Task Unit Observation
Downtime Mins 84
CIP Mins 90
Batch Cooking Time Mins 50
Rework Bottles 412
Break Time Mins 35
Cooler Bottles 2676
Operating Time Mins 191
Downtime loss Bottles 10080
Prod/Shift Bottles 19832
Downtimes
Minor Stoppages
Point Electrical Mechanical Utility Total
Time (min) Time (mins) Time (mins) Time (mins)
Jar Feeders 0 16 0 16
Conveyors 0 0 0 0
Washer 0 0 0 0
Filler 0 0 0 0
Capper 0 8 2 10
Cooling Tunnel 0 7 0 7
Labeller 0 4 0 4
Jar Coding 0 0 0 0
Tray Coding 0 0 0 0
Shrink Wrap 0 0 0 0
Total 0 35 2 37
Major Stoppages
56
Point Electrical Mechanical Utility Total

Time (min) Time (mins) Time (mins) Time (mins)
Jar Feeders 0 0 0 0
Conveyors 0 30 0 30
Washer 0 0 0 0
Filler 0 0 17 17
Capper 0 0 0 0
Cooling Tunnel 0 0 0 0
Labeller 0 0 0 0
Jar Coding 0 0 0 0
Tray Coding 0 0 0 0
Shrink Wrap 0 0 0 0
Total 0 30 17 47
7.1.2 Boilers
1) Boilers are necessary for any industry to produce steam for two major purposes, to
produce pressure and heat.
2) For these purposes, in Mitchells, there are two types of boiler i.e. oil/gas boiler and
coal/wood boiler.
3) There are two gas boilers having a maximum capacity of 4 tons/hour each.
4) Coal based boiler is a new one imported from china just two years back, with very high
capacity of 10 tons/hour.
5) In coal boiler, we can achieve a maximum pressure of 10 bars at 182˚C but usual
operating pressure is 7 bars at 173˚C.
6) In boiler, there is a water considered as optimum that is +20, while its has a range of -50
to +50, water level should not be down to +20.
7) Usually the temperature of feed water is 40˚C which is increased by an economizer
(increase temperature of feed water by exhaust gases) to 90˚C just before feeding.
8) The pressure of feed water pump should be more than the pressure in boiler to prevent
back flow.
57
9) The pH of boiler water should be between 10.5 to 11.5 to prevent the attack of oxygen
and rust.
10) Maximum TDS of boiler water should be below 3500 ppm. When the pH of exhaust
water (containing exhaust gases of boiler) lows down to 2-3 then change the water or add
caustic soda to increase it pH.
11) Feed water analysis includes the hardness of water and TDS.
12) Boiler water analysis contains the tests for Hardness (CaCO3, MgCO3, phosphates,
sulphates), pH, and TDS.
7.1.3 Water treatment plant

Today we visit the water treatment plant which treat all drain water comes from all production
plants where water is excessively used .When water of production plant is drained out, it consist
of different organic & inorganic material which cause harmful effects on environment and life.
For this purpose Factory management team has established the waste water treatment plant to
prevent this action. This plant is working 24 hours automatically. Whenever the water level of
main tank cross the limit the pump is automatically on and starts feeding to aeration tank.
Plant consists of three major parts.
1) Main tank
2) Aeration tank
3) Clarifier tank
Main Tank:
Waste water of all production plants accumulate in this tank through pipes. There is a
set point in tank, when water accumulates at that point then feeding pump automatically on and
feed the water into the aeration tank and this process continuously.
58
Aeration tank:
A compressor is set up near the tank which compress the air and provides that air in
the aeration tank .In this tank, we also provides media ( DAP 5 kg and Urea 15 kg) for the
growth of microorganism like Bacteria . After that process, bacteria growth starts in the presence
of oxygen and fertilizers. Bacteria decompose the organic matter which is present in waste water.
Gradually, water moves to the Clarifier tank.
Clarifier tank:
In this tank, agitator is worked out at 3 rpm through this agitator water moves slowly
due to which sludge is settle down. Clarified water float up and moves out of the tank by small
spaces present on top the tank. This water drained out in a nearly situated canal.
7.1.4 Overall Equipment Effectiveness (OEE)

We learned about OEE and apply on a chocolate molding plant.
OEE consist of three basic aspects which are following
1) Availability %
2) Performance %
3) Quality %
Availability %:
It is the ratio of running time of machine and total available time and multiplies
with100.
Availability% = Running time/Total available time x 100
For example, Total shift time is 480 mints and our planned time is 80 mints (50 mints for CIP
and 30 mints for brake time) and in this way our available time is 420 mints. In available time, if
running time is 365 mints and remaining time is lost due to down time losses then our
availability % is following
Availability% = 365/420 x 100 = 86.90%
Performance %:
It is the ratio of actual production by a machine and a standard production by a
machine and multiplies with 100.
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Performance % = Actual production/Standard production x 100

For example, if standard speed of machine is 122 jars/ mint then standard production in running
time should be
Standard production = 365 x 122 = 44530 jars
In this way, if machine is working at 109 jars /mints instead of 122 jars /mint then our total
production will be
Actual production = 365 x 109 = 39785 jars
Using the formula, we can calculate the performance %
Performance% = 39785/44530 x 100 = 89.34%
Quality%:
It is the ratio of good production to total production multiplies with 100.
Good production:
It is the quantity of products which remains after rework and visual inspection
as original production.
Quality% = Good production/Total production x 100
For example, if our total production is 39785 jars, after rework and visual inspection the
remaining jars is 39112 jars.
Rework = 39785 – 673 = 39112 jars
That jars is our Good product and in this way we calculate the Quality% by using the formula
Quality% = 39112/39785 x 100 = 98.30%
Calculation of OEE = Availability x Performance x Quality
7.1.5 Syrup Section
60
Syrups and syrup juice mixtures are prepared by using Pearson’s formula.
Q. Make a 650 kg juice of 40˚Brix from sugar syrup of 72˚Brix and mango pulp of 16˚Brix.
Now solve this as (Brix)

(Required - Pulp) + (Syrup - Required)
(40 – 16) + (72 - 32) = 56
Syrup %age:
= 24/56 x 100 = 42.85
Syrup Required (Qty):
= 42.85/100 x 650 = 278.57 kg
Pulp %age:
= 32/56 x 100 = 57.14
Pulp Required (Qty)
= 57.14/100 x 650 = 371.42 kg
Q # 2: Make a syrup of 80˚Brix from 30 kg sugar.

Syrup = 100/80 x 30 = 37.5 kg
Required Water = 37.5 kg – 30 kg = 7.5 kg
Q # 3: Make 800 kg syrup of 67˚Brix.
Required Sugar = 67/100 x 800 = 536 kg
Required Water = 800 – 536 = 264 kg
7.1.6 Weekly Progress Reports

First Day at Mitchell’s
Our first day at Mitchell’s was 22nd of June 2015. Human Resource manager (Sheikh Naveed
Ahmed) refers us to our Incharge Mr.Shoaib Awan (Plant operation manager) who took a short
introduction about our studies and residence and call Mr.Waseem (Grocery plant Supervisor)
who visits us whole industry sections which includes:
1) Grocery plant
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2) Confectionary plant
3) Pulping plant
And give us detailed instruction about processing. Then internship letter was issued from HRM
office which contains timing, instructions and schedule of our working days.
Introduction is briefly described above.
1st Week Progress

1) On Monday, we are visited the whole industry Plants & sections.
2) On Tuesday, we learn about the processing of Jam-e-hayat.
3) On Wednesday, We worked on the Sauce line and learn the processing of Chili Garlic
Sauce and asked about the question.
4) On Thursday, Our Incharge has assigned a duty in confectionary plant and we saw whole
processing of MCE (Milk chocolate éclairs) soft candy.
5) On Friday, our task was Quality parameters of Jam -e- hayat and we checked it regularly.
6) On Saturday, We learn about the whole processing of Hard Candy.
2nd Week Progress

1) On Monday, our Incharge has assigned a duty in Pulping plant where we are worked on
the processing of Chick pea.
2) On Tuesday, our duty was in main lab where we learn and perform the different quality
analysis tests.
3) On Wednesday, we worked on the preserve line /jam line and learn about Golden mist
Marmalade processing and quality parameters.
4) On Thursday, we worked on Variance Analysis and calculate the total production in shift.
5) On Friday, We learn about the processing of lemon squash on the Squash line.
6) On Saturday, Our duty was in Chocolate Molding plant and learns about the processing
of Jubilee.
3rd Week Progress

1) On Monday, we worked and observe the whole processing, canning & in pack
sterilization of Sag.
62
2) On Tuesday, our duty was on preserve line where we observe the processing, filling
speed, capping, coding, labeling, and packaging of Ginger paste.
3) On Wednesday, we worked on processing of Garlic ginger paste and quality parameters.
4) On Thursdays, We perform the different quality analysis tests in main lab.
5) On Friday, our task was in pulping plant where we saw the whole processing and
chemical mixing of mango pulp.
6) On Saturday, our incharge has assigned a duty to check the quality parameters of Mango
pulp.
Conclusion
The production & quality control Department of Mitchell’s Fruit Farms Ltd. seems to be catering
to the needs and wants of the customer & employees very effectively and efficiently. But issues
like decentralized- decision making is still lacking. The control is mostly in the upper levels. But
the good aspect is that they treat their lower levels in a nice manner. Also the production and
quality control department is still going under its initial changes and need time to get settled in
the organization. As the technological advancement, is getting more intense with the passage of
time, the production department & quality control of Mitchell’s Fruit Farms Ltd. is trying its best
to settle the employees within the organization according to this advancement. The practices they
are performing in the organization and its rapid growth shows its effectiveness and the accepting
behavior of their employees shows they want this new change in the environment and want to
grow with the organization. Overall production & quality control department of Mitchell’s is
performing well; it is also providing its employees opportunities for their career development
and for their better future. I conclude
1) I did work in all 4 sections of Mitchells
2) Grocery, jam-e-hayat, orange squash, chick pea
3) Confectionary, soft and hard candy
4) Pulping plant, mango pulp (aseptically filled)
5) Chocolate Moulding Plant (Jubilee)
6) Case studies (OEE, Downtimes, Syrup Preparation)
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7) Maximum products exported

8) Meet international standards
9) Good performance
10) Links country product standards
11) Effective coordination with workers
12) Lack of worker safety implications
13) Management has main focus on quality
Suggestions / Recommendations
1) There are some machines/motors which are not covered, so they should be covered to
reduce accidents.
2) Some powerful motors when on they produce high vibrations due to which nearly present
pipes and other things shakes, which is dangerous.
3) The free friendly environment of workers during working can harm them. Worker’s
concentration should be totally on their work.
4) Washing the machines during filling of product produce splashes which can cause
contamination of food products, it should avoid.
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References
Resource persons
1) Mr. Shoaib Awan (Plant Operation Manager)
2) Mr. M. Idrees
3) Mr. Muhammad Umair Butt (Quality Assurance Manager).
4) Mr. Shoukat Ali (R & D Lab Supervisor)
5) Mr. M. Ashiq (QA. Lab Supervisor)
6) Mr. Zohaib Ayub (Quality Assurance Officer)
7) Mr. Fazal Abbas (Quality Assurance Officer)
8) Mr. Qasim Sikandar ( Microbiologist)
Website
www.mitchells.com.pk
65

Hammad Hafeez Ahmad Raza: The Islamia University of Bahawalpur

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PROCESSING AND PHYSICOCHEMICAL

ANALYSIS OF GROCERY & CONFECTIONERY

B.Sc (Hons) Agriculture

Department of Food Science & Technology

The Islamia University of Bahawalpur

My ineffable in deftness is due to Dr. Zulfiqar Ahmad (Assistant Professor)

1.1 History of Mitchell’s fruit farms limited 8

1.5 Quality Policy 9

1.6 HACCP policy 10

1.7 GMP policy 10

1.8 ISO-9001 Certification 10

2 DEPARTMENTS AND ADMINISTRATION 11

2.1 Departments in Mitchell’s fruit farms ltd. 11

3.1 Grocery products 12

3.2 Confectionary products 13

3.3 New Products 13

4.2 Important Machine Working in Processing Plant At MITCHELL’S 23

5.1 Grocery Section 24

5.2 Confectionary Section 40

5.3 Moulding Plant 43

5.4 Pulping Plant 47

6 QUALITY ASSURANCE DEPARTMENT 51

6.2 Main Lab Tests 52

1.1 History of Mitchell’s fruit farms limited

1.5 Quality Policy

c) To be a company which optimally combines its people, technology, management system

1.6 HACCP policy

1.7 GMP policy

1.8 ISO-9001 Certification

2 DEPARTMENTS AND ADMINISTRATION

2.1 Departments in Mitchell’s fruit farms ltd.

General Manager Mr. M. Mujeeb

Factory Manager Mr. Shoaib Awan

Production Mr. Shoaib Awan

Engineering Mr. Iftikhar

Store Mr. M. Shokat

Sales Mr. Haji Habib

Purchase Mr. Nadeem

Security Mr. Farquleet Zafar

H.R. Department Mr. Shaikh Naveed

Total Products: 15 Total Products: 22

Total Products: 20 Total Products: 19

Total Products: 13 Total Products: 17

Total Products: 22 Total Products: 10

3.3 New Products

2) Fruitica Orange (Instant Drink)

3) Fruitica Lime (Instant Drink)

4) Yum! Ketchup Stand-up Pouch (500g)

5) Top Milk Fruit & Nut

8) Apple Jelly Junior

9) Golden Mist Marmalade Junior

10) Strawberry Jam Junior

11) Mixed Fruit Jam Junior

12) Mango Jam Junior

13) Golden Apple Jam Junior

14) Hot & Sweet Sauce

15) Synthetic White Vinegar

16) Yum! Ketchup Stand-up Pouch

17) Lychee Fruit Drink

19) Apple Fruit Drink

20) Mango Hyderabadi Pickle

21) Mixed Hyderabadi Pickle