g

Research Project and Report Writing

ZA Food Industry

GCUF Govt. College University Faisalabad 8th Semester

 Research Project Report
At
ZA Food Industry

Submitted by:
MUHAMMAD SOHAIL AKRAM
Roll No. 3258
8th Semester (Morning)
B.S (Hons) Food Science and Technology
Institute of Home & Food Science
Govt. College University Faisalabad

Duration of Internship:

2 and Half Months (10th March 2016 to 15th May 2016)

GCUF Govt. College University Faisalabad 8th Semester

 Internship Report Approval Sheet
The undersigned certify that they have read following report, examined the presentation,
are satisfied with overall performance, and recommend the report to Department of Food
Science and Technology studies for acceptance.

Report Title: ZA FOOD INDUSTRY

Bachelor of Science- Food Science & Technology (BSFS&T)

Dr. Tahir Nadeem

Assistant Professor
Department of Food Science and Technology

Signature

Dr. Faqir Muhammad Anjum

In charge of Department
Department of Food Science and Technology
Signature

GCUF Govt. College University Faisalabad 8th Semester

 In the name of ALLAH the most merciful and beneficent

"It is he who sends down rain from the skies:

With it we produce vegetation of all kinds:
From some we produce green (crops) out of
Which we produce grain heaped up (at harvest);
Out of the date-palm and it sheaths (or spathes)
(Come clusters of dates hanging low and near:
And (then (there are) gardens of grapes and olives
And pomegranates each similar (in kind) yet
Different (in variety): when they begin to bear
Fruit and the happiness thereof. Behold! In these
Things there are signs for people who believe."

Al- Quran Al-Anam-99

GCUF Govt. College University Faisalabad 8th Semester

 Our Beloved Parents and Respected Teachers

Who guided us to the right path!

Who was the inspiring force behind each and every step we took
forward in our life.

Especially to our friends who encourage us and guide us to right

path to future.

GCUF Govt. College University Faisalabad 8th Semester

 Acknowledgement

All Praises and Thanks for Almighty Allah, The most compassionate and merciful, Who
knows whatever is there in the universe, hidden or evident and is entire source of all
knowledge and wisdom to mankind. We offer our humblest thanks to Holy Prophet
Hazrat Muhammad (Peace Be Upon Him), who is, forever a torch of guidance and
knowledge for humanity.
We grateful to thank Dr. Faqir Muhammad Anjum (In charge of Department,
Department of food science and technology, Govt. College University Faisalabad for
providing me support during this study time. We feel great pleasure in expressing
gratitude to Sir Tahir Nadeem (Assistant Professor, Department of food science and
technology, Govt. College University Faisalabad who has always guided, supported and
encouraged me during my internship.
We also thankful to Mr. Zulfiqar Ahmed (Managing Director), Mr. Saleem (Shift
Incharge), Mr. Mazhar, Mr. Nadeem (Candy Incharge), and Mr. Meer Abbas
(Toffee Incharge) for their guidance, encouragement and valuable suggestions during
whole of my internship period. We also thankful to all staff members of the factory who
were very cooperative to me during my internship period.
Heartiest thanks are goes to my sweet parents for their moral and financial support that is
scarified for us so that we are entirely free to devote ourselves to studies. They always
encouraged us whenever we were demoralized during our academic career. We are also
thankful to our friends for always supporting us.

MUHAMMAD SOHAIL AKRAM

ROLL # 3258
8TH SEMESTER

GCUF Govt. College University Faisalabad 8th Semester

 Table of Contents

Chapter # 1 Crystal’s Top Products

Chapter #2 Bubble Gum Section

Chapter #3 Chocó Bean Section

Chapter # 4 The Sixer Section

Chapter #5 Chew Toffee Section

Chapter #6 Candy Section

Chapter #7 Lollipop Section

Chapter # 8 Deposit Candy

Chapter # 9 Certifications

GCUF Govt. College University Faisalabad 8th Semester

GCUF Govt. College University Faisalabad 8th Semester
A. candies
1. Khopra candy
2. Mango twist
3. Milk twist
B. Centered Filled Candies
1. Best every candy
2. Chilchilafrooty candy
3. Coconut frooty candy
4. Annar frooty candy
5. Orange frooty candy
6. Guava frooty candy
7. Qualfa candy
8. Pan froooty candy
9. Amrood Twist candy
C. Toffees
1. Éclair’s Toffee
2. Badamikhoa toffee
3. Strawberry Toffee
4. Scary Chew orange
5. Party Treat Chew
6. Stinger Cola Chew
D. Lollipop
1. Mr. Zorro Tuttifruity
2. Mr. Zorro orange
3. Mr. Zorro strawberry
4. Froveli lollipop
5. Milko Lollipop
6. Milk Lollipop
7. Paint magic
8. Fruity mix lollipop
E. Bubble Gum
1. Spiderman bubble gum

GCUF Govt. College University Faisalabad 8th Semester

 2. Sour punch bubble gum balls
3. Orange flavor gum
4. Strawberry flavor gum
5. Fresh ball orange gum
6. Fresh ball red gum
7. Fresh ball green gum
8. Fresh ball cyan gum
9. Full fresh’o strawberry gum
10. Full fresh’o mint flavor gum
11. fullfresh’o tropic flavor
F. Sour Chew Bar
1. Stinger Cola Chew
2. Stinger orange Chew
3. Stinger tutti fruity Chew
4. Stinger grapes Chew
5. Stinger blue Chew
6. Stinger apple Chew
7. Strawberry scary chew
8. Orange scary chew
9. Blueberry scary chew
10. Apple Scary chew
11. Party treat chew
G. Chocolate
1. Choco milk Pouch
2. Choco milk jar
3. Choco Milk Box
H. Choco Beans
1. Choco Crunch beans Box
2. Choco Mobile Beans box
3. Mini’s choco box
I. Mixed products (others)
1. Ahmed Golden Jublee

GCUF Govt. College University Faisalabad 8th Semester

 2. Ahmed Jublee box
3. Butter toffee
4. Khoya Toffee box
J. Export Products
1. Sajak Heal
2. Give Me
3. Fresh Gum
4. Dubai Gum

GCUF Govt. College University Faisalabad 8th Semester

GCUF Govt. College University Faisalabad 8th Semester
Ingredients:
1. gum base
2. corn syrup
3. sugar
4. glycerol
5. soy lecithin
6. color
7. glucose
8. gum Arabic
9. Others (aspartame)
Gum base:
Types:
Generally three types of gum base are used there:
1. CNF (China Gum Base)
2. Zarcon T.
3. Master (Brazilian)
Ingredients:
1. Elastomer
2. Resins
3. Waxes
4. Fat
5. Emulsifier
6. Filler
7. Antioxidant
Functions of Ingredients:
1. Elastomer provide elasticity or bound
2. Resins: provide cohesive body or strength
3. Waxes: act as softening agent, commonly paraffin, microcrystalline wax.
4. Fat: behave as plasticizer
5. Emulsifier: help to dehydrate commonly lecithin and mono-stearate.
6. Antioxidant: protect from oxidation or intend the shelf life.

GCUF Govt. College University Faisalabad 8th Semester

Processing of Bubble Gum:
Step I
 Mixing: firstly add gum base (authenticated by icga), talcum powder, glucose,
lecithin for 3 – 4 min.
Step II
 Add the sugar and mix it for 5 – 6 min.
Step III
 Add the sugar and mix it again for 5 – 6 min.
Step IV
 Add remaining of the sugar
 Citric acid
 Flavor
 Apply homogeneous mixing for 3 – 4 min at the temperature of 70oC to 75oC.
Equipment used in bubble gum:
1) Weighing balances:
Digital weighing balances are used to weigh different bread ingredients. There are two
types of balances at plant:
a) Large balance: Used to weigh flavor and sugar.
b) Small balance: Used to weigh different ingredients in small fractions (yeast,
improver, salt, etc.)
2) Mixer:
Z – Mixer: It is used for biscuit mixing. The mixer is usually a wheel-mounted, heavy
tub with vertical sides round ends, and a flat bottom. The mixer is designed so that it may
be wheeled into the position below the mixer head and locked into place. The spindles are
lowered into the mixer and move in either a planetary or stationery, circular motion when
activated. The mixer blades are designed to provide a cutting action rather than kneading
or stretching the dough.

GCUF Govt. College University Faisalabad 8th Semester

GCUF Govt. College University Faisalabad 8th Semester
Ingredients:
 Sugar
 Fat
 Milk
 Chocolate
 Lecithin
 Flavor (chocolate)
Processing:
Step I
 Mixing
Step II (Shaping and Rolling)
 Product is passed through from a die machine that give the product shape and
chilling the bunti.
 By a conveyor belt product goes to a sieving drum.
 Small size bunti pieces fall down in an iron sheet and sizable pieces are collecte d
in basket.
Statistical analysis:
 Small size choco-bunti: ½ kg in one minute is produced.
 Large size bunti: 1 kg in one minute is produced.
Coating area:
 This is done in rolling drum with cooled ari that dry the product.
 Coating area temperature is 4oC – 7oC.
Drum capacity:
 100 kg product can be coated in one time.
 15 – 20 drums are available in coating area.
Coating materials:
 Sugar, titanium dioxide powder, water added in drum cup by cup.
 Allow to dry it then again added in drum.
 Add color (desired color).

GCUF Govt. College University Faisalabad 8th Semester

  Polishing
Coating benefits:
 Coating increases the bunti weight.
 Coating time is 8 – 16 hours is required.
 Bunti (choco beans) weight 12 – 14 g.
PACKAGING AREA:
 Sieving requires before packaging is done so that the damage particles may
avoided from final product.
Machines for packing:
Three types of machines are used:
1. Patch machine (blister packing machine)
2. Mobile bunti machine (automatic plate blister)
 Model APB-22 (Pharmaceutical)
3. Pouch machine (blister packing machine)
4. Rigid PVC are used to pack bunti.
PVC specification:
 Thickness is 0.16 mm.
 Width is 280 mm/inch.
 Net weight is 17 – 170 kg.

GCUF Govt. College University Faisalabad 8th Semester

GCUF Govt. College University Faisalabad 8th Semester
Sixer is the first famous product of ZA FOOD INDUSTRY which lead to the industry to
its peak position. The specification of this product is that there is no chemical (colorant or
flavor) used. So it may call as safe product for children throat and other health concerns.
Ingredients:
 Sugar
 Water
 Glucose
 Coconut
Processing:
1) Add sugar and water in open pan on the fire to dissolve the sugar.
2) Cooking temperature 131 oC.
3) Cooking time varies according to environmental conditions. So the average time
is 15 – 20 min.
4) Mixing: Cooked material is panned out in a mixer to mix the coconut in it.
5) The dough type material put out at the table and allow to cool.
6) Molding: Extruders are sued to mold the dough and give the shape.
7) Cooling and Conveying: Conveying and cooling is done at a same time to save
the time.
8) After cooling the primary cutting of dough into small pieces.
9) Resting: Keep the final shaped product for 24 hours resting time at room
temperature.
10) Coating: Caramel color, chocolate, and sugar is used to form the coating material.
These ingredients are mixed and cooked in open pan. Prepared material and
product is mixed in rolling drum for the purpose of coating. Blowers are also used
to dry the coating.
11) Polishing: Polishing material add in the drum and processing done for 5 – 10 min.
12) Packaging machine efficiency: 500 to 1000 piece is packed in one minute.

GCUF Govt. College University Faisalabad 8th Semester

Flow sheet diagram for sixer:

Mixing and Cooking

Molding

Conveying

Coating

Packaging

GCUF Govt. College University Faisalabad 8th Semester

GCUF Govt. College University Faisalabad 8th Semester
A sweet blend of various flavors made from chicle for chewing (a gum prepared for
chewing: sweetened and flavored)
Ingredients:
1) Ghee
2) Poly-dextrin powder
3) GMS + glucose powder + soya lecithin sugar solution
4) Liquid glucose
5) Flavor
6) Citric acid (occurs naturally in citrus fruits but may also be prepared from the
fermentation of molasses. Used as an antioxidant, preservative, acid regulator.)
7) Water
8) Color
9) Gelatin (protein extract from animal bones and tissue. Used as a stabilizer and
jelling agent.)
10) Butter fat
Processing:
 Batch preparation:
Cooking:
Add ghee, dextrin solution, GMS, liquid glucose, soya lecithin and sugar solution, in
double jacketed cooker heated by the steam. Cooking temperature is 125oC for 25
minutes. Stirring is continuously done for 25 min.
Addition of color:
Some colors are added in cooking pan during cooking (for example cola and grapes) and
some colors are added after cooking e.g. raspberry, orange, and vanilla. After cooking
sorbitol syrup is also added in a small amount.
Cooling:
Batch is cooled on a cooling table for 10 to 15 min. Cooling table is a metal table which
contains tube network on its lower side in which fresh water continuously flows and
cools the batch.
Pulling:

GCUF Govt. College University Faisalabad 8th Semester

Pulling is done by pulling machine which increases the elasticity of the chew and makes
its texture soft. Flavor mixing is also done during pulling. Pulling time is normally 2 – 9
minutes depending upon the required texture. The volume of the product can be increased
by increasing the puling time due to whipping i.e. incorporation of air to the product.
Pulling also helps in graining.
Forming:
Batch is cooled for 2 – 3 min. Then fed to batch roller machine it make circular role of
the batch. Sometime powered is also filled between the chew through worm. Sizes give
the proper size and shape of the chew piece. Some kinds of chew candies are also coated
as mention in the bubble gum coating.
Wrapping and Packaging:
Different types of wrappings are used for example pillow wrap and twist wrap. Then
finally chew is packed into pouches of 50 and 100 pieces.
Flavors
 Cola
 Ice cream
 Raspberry
 Milky
 Oranges
 Grapes
 Strawberry
Trouble shooting in chew toffee:
1. Leakage of chew toffee:
It is due to cooking at low temperature cooking and improper sealing of chew toffee
during wrapping. To avoid leakage problem, cook, and seal properly.
2. Graining:
If concentration of glucose is more and high cooking temperature then graining in the
chew toffee would be less.

GCUF Govt. College University Faisalabad 8th Semester

GCUF Govt. College University Faisalabad 8th Semester
The Arabs’ word for it was qandi, from qand, a lump of sugarcane. It came down to us,
virtually intact, through successive. European languages; old Italian (zuccherocandi), old
French (sucrecandi), middle English (sugar candi). In the 1800s, Americans called it
“sugar candy.” Now, it’s just candy. It is indeed virtually entirely sugar, with a few minor
glamorizes tossed in for color. There are two types of candies; i) hard candies (1.5 – 2%
moisture content), and Soft candy (marshmallows nougats 4 – 6% moisture contents.)
Ingredients:
1. Sucrose
2. Liquid glucose (corn syrup)
3. Color
4. Flavor
5. Citric acid
Preparation of High Boiled Candy
Cooking:
Concentrating the solution is the main task of cooking process. Sugar and liquid glucose
are added in the cooker. Cooking temperature is 130oC and vacuum is kept 700 mmHg.
Cooking is done for 10 min. vacuum helps to reduce the moisture contents at lower
temperature i.e. 130oC otherwise without vacuum candy cooking requires 160oC. At this
high temperature browning of sugar (caramelization) can be a problem.
Cooling:
After cooking shift the batch to cooling table, where the batch is cooled to 100oC for 5 –
10 min so that the dough should not cause problem afterwards. Citric acid is added at this
stage as spray of powder.
Kneading:
Move the batch from cooling table to the kneading machine for complete homogenization
and proper mixing of citric acid for 5 – 10 min. Flavor is also blended during kneading
process.
Forming and cutting:
After kneading, the batch is conveyed to the tri-roller machine. Roller machine has
heaters to maintain the temperature of the dough to 90 – 100oC. It makes the shape of
dough into the rope. Rope move to the sizer which gives the proper size to the rope.

GCUF Govt. College University Faisalabad 8th Semester

Cooling:
This dough passes to the die that cut it in to the required shape of candy. Cooling process
is also involved here. Shifting conveyor passes the candy to the cooling conveyor that has
three stages. Air from blowers cools the candy and makes it hard.
Wrapping and packing:
Candies are shifted to pillow wrap machine or twist wrap machine where candies are
wrapped and then packing is carried out in the plastic bags or glass jars.
Wrapping machine efficiency:
 Sign piece packing machine efficiency:
o 700 pieces/min.
o Model# DE 500.
 Vertical form-fill seal machine efficiency:
o 20 – 65 bags/min.
 Bas size: Length 100 – 280 mm, width 70 – 240 mm.
 Filling range: 50 – 1500 ml.
 Film material: PET, PE, etc.
 Weight: 600 kg.

GCUF Govt. College University Faisalabad 8th Semester

GCUF Govt. College University Faisalabad 8th Semester
Ingredients:
 Water
 Sugar
 Glucose
 Citric acid
 Color
 Flavor
Processing:
 Take water in cooker and add the sugar in it.
 Open the steam valve and start mixing.
 At the temperature of 95 – 100oC and add glucose in it.
 At the temperature of 144oC, the material will totally be cooked.
 Close the steam valve, take out the material room cooker and put on the table.
 Add citric acid, color, and flavor.
 Cooking time is 15 min.
Packaging area:
 Machine speed set at 134 pieces/min.

GCUF Govt. College University Faisalabad 8th Semester

GCUF Govt. College University Faisalabad 8th Semester
Ingredients:
 Sugar
 Glucose
 Milk
 Fat
 Lecithin
 Flavor (kulfa)
 Titanium dioxide
 Salt
Processing:
 Add sugar and water in cooker and start for mixing.
 At the temperature of 95 oC to 100 oC. Add glucose in it and continue the mixing
still boiled.
 At the temperature of 122 oC, add milk, lecithin, and salt.
 Close the steam, and transfer the material in store tank.
 After transfer the material adds titanium dioxide powder is store tank.
 Material will be transferred in micro film cooker by pipe line.
 Material will be cooked at the temperature of 145 oC – 255 oC (recommended
temperature.)
 If the temperature will be high from 155 oC, then the material would be like
(karwa) and if temperature low from 145 oC then the material will not be mixed
properly.
 Thus this will create disturbance when the material comes in dye.
 Now the material is transferred in hopper.
 Hopper has nozzle and heater which transfer the material in dye.
 Heater keeps the material hot.
 On the top the hopper, a separate small mixer that mix the material in hopper.
 Air jacket function: Air jacket pick the conveyor to the upper side and nozzle fil
the material in dye.
 Hopper heater has the temperature of 165 – 145oC that keep the material hot.
 Flavor will be added in double jacket pipe not in motor.

GCUF Govt. College University Faisalabad 8th Semester

  Blower is attached in conveyors upper side that cools the product.
 On conveyor belt, a roller machine that pushes the pin 0contain filling material.)
 After the pushing, candy will take out from die (on conveyor belt.)
 At the end a sieve is used to remove the de-shaped or small piece.

GCUF Govt. College University Faisalabad 8th Semester

 Flow Sheet Diagram of Candy

Sucrose Color

Cooking
130oC
700 mmHg Glucose

Cooling (100oC, 10 min)

Flavor

Kneading (10 min) Citric

Forming

Cooling, 25oC

Wrapping

Packing

Packaging Storage

GCUF Govt. College University Faisalabad 8th Semester

Flow Sheet Diagram of Bubble

Weighing

GMS Gum base

Batch Preparation
in kneading
machine: 1
100oC

Soya lecithin Talcum Powder

Processing

Cooling

Block Forming

Storage

GCUF Govt. College University Faisalabad 8th Semester

Hazard Analysis and Critical Control Points (HACCP) System and
Guidelines for its Application in Chew
HACCP:
The HACCP system, which is science based and systematic, identifies hazards and
measures for their control to ensure the safety of food. Any HACCP system is capable of
accommodating change, such as advances in equipment design, processing procedures or
technological developments. As well as enhancing food safety, implementation of
HACCP can provide other significant benefits. In addition, the application of HACCP
systems can aid inspection by regulatory authorities and promote international trade by
increasing confidence in food safety.
The successful application of HACCP requires the full commitment and involvement of
management and the workforce. The application of HACCP is compatible with the
implementation of quality management systems, such as the ISO 9000 series, and is the
system of choice in the management of food safety within such systems.
While the application of HACCP to food safety was considered here, the concept can be
applied to other aspects of food quality.
Principles
The HACCP system consists of the following seven principles:
Principle 1: Conduct a hazard analysis.
Principle 2: Determine the Critical Control Points (CCPs).
Principle 3: Establish Critical Limits.
Principle 4: Establish a system to monitor control of the CCP.
Principle 5: Establish the corrective action to be tken when monitoring indicates that a
particular CCP is not under control.
Principle 6: Establish procedures for verification to confirm that the HACCP system is
working effectively.
Principle 7: Establish documentation concerning all procedures and records appropriate
to these principles and their application.
Application of HACCP in chew
The application of HACCP principles consists of the following taks as identified in the
logic sequence for application of HACCP:

GCUF Govt. College University Faisalabad 8th Semester

 1. Assemble HACCP team
2. Describe product
3. Identify intended use
4. Construct flow diagram
5. On-site confirmation of flow diagram
6. List all potential hazards associated with each step, conduct a hazard analysis, and
consider any measures to control identified hazards (see principle 1.)
More than one control measure may be required to control a specific
hazard(s) and more than one hazard may be controlled by a specified control
measure.
7. Determine critical control points (see principle 2)
There may be more than one CCP at which control is applied to address the same hazard.
The determination of a CCP in HACCP system can be facilitated by the application of a
decision tree, application of a decision tree should be flexible, given whether the
operation is for production, slaughter, processing, storage, distribution, or other. It should
be used for guidance when determining CCPs.
8. Establish Critical Limits for each CCP (see principle 3)
Critical limits must be specified and validated if possible for each critical control point.
9. Establish a Monitoring System for Each CCP (see principle 4)
The monitoring procedures must be able to detect loss of control at the CCP. Further,
monitoring should ideally provide this information in time to make adjustments to ensure
control of the process to prevent violating the critical limits.
10. Establish Corrective Actions (see principle 5)
Specific corrective actions must be developed for each CCP in the HACCP system in
order to deal with deviations when they occur. The actions must ensure that the CCP has
been brought under control.
11. Establish Verification Procedures (see principle 6)
Establish procedures for verification. Verification and auditing methods, procedures and
tests, including random sampling and analysis, can be used to determine if the HACCP
system is working correctly.
12. Establish Documentation and Record Keeping (see principle 7)

GCUF Govt. College University Faisalabad 8th Semester

Efficient and accurate record keeping is essential to the application of a HACCP system.
HACCP procedures should be documented.
Training
Training of personnel in industry, Govt. and academic in HACCP principles and
applications, and increasing awareness of consumers are essential elements for the
effective implementation of HACCP. As an aid in developing specific training to support
a HACCP plan, working instructions and procedures should be developed which define
the tasks of the operating personnel to be stationed at each critical control point.

GCUF Govt. College University Faisalabad 8th Semester

GCUF Govt. College University Faisalabad 8th Semester
GCUF Govt. College University Faisalabad 8th Semester
GCUF Govt. College University Faisalabad 8th Semester
GCUF Govt. College University Faisalabad 8th Semester
GCUF Govt. College University Faisalabad 8th Semester
GCUF Govt. College University Faisalabad 8th Semester