Training Report on Britannia Industries

Under Guidance
Er. Ashwani Duggal
HOD (Department of Food and Agricultural Engineering)
Faculty of Engineering& Technology
Mr. Vinod Dwivedi (Production officer)
Britannia industries

For The Partial fulfillment of the Degree of

Bachelor of Technology in Food Technology

Submitted To,
Mr. Vinod Dwivedi (production officer)
Mr. Gaurav Chaturvedi (Quality officer)

Completed By
Vikas kumar Panday

B. Tech (Food Technology)

VI Semester (2009-13 Batch)

Department of Food and Agricultural Engineering

Faculty of Engineering& Technology

Mahatma Gandhi Chitrakoot Gramodaya University Chitrakoot,

Satna (MP)
 ACKNOWLEDGMENT

It gives me great pleasure to express to my thanks & heartfelt gratitude to my guide, Mrs.
Ashwani duggal, Department of Food Technology, M.G.C.G.V. Chitrakoot for her valuable
guidance Food Technology, continuous encouragement & inspiration. This project work would
not have been materialized; I am greatly indebted to her.

I would like to express my sincere thanks to Er. Ashwani Duggal, Head, Food
Technology, M.G.C.G.V. Chitrakoot, and other members of department of food technology ,for
their kind help to carry out the work ..

I am also thankful to Mr. Hari Sir (Chairman, Bhagwati Foods) who Provided me
Opportunity in his industry to gain knowledge, also I would like to thank Mr. Joshi Ji (G.M) &
Sudheer Ji (M.D).

I am extremely grateful to Mr. Vinod Dwivedi (Production Officer, Brittania) who

provided me guidance in my each and every step & cleared my doubts every time i went to him.
He also provided me valuable scientific as well as conceptual Knowledge which will definitely
help me in my future work, and very heartful thanks to Mr. Gaurav Chaturvedi (Quality officer,
Britannia) in Bhagwati biscuits Pvt. Ltd for providing me an opportunity and all the necessary
facilities in the plant related to Quality aspect.

I am very thankful to Mr. Prashant Singh Sachan (Quality Manager), Mr. Rajesh (Lab Chemist),
Mr. Sanjay Sharma & Mr. Sumit Verma for his kind and friendly support in the lab. Finally, I
thank one and all who have helped me directly or indirectly for the Purpose.

Place: Kanpur (Vikash kumar Panday)

 Content
1. Introduction of Britannia Industries and Bhagwati Foods Pvt Ltd

2. Use of ingredient and its role

3. Laboratory

4. Mixing

5. Function of Rotary

6. Function of oven

7. Full process of Biscuits making

8. Use of Sieves standard

9. Daily Quality Index

10. Daily Assignment on oven section

11. Daily Assignment on Packaging Section

12. Conclusion
 INTRODUCTION OF BRITANNIA INDUSTRY

The story of one of India's favourite brands reads almost like a fairy tale. Once upon a time, in 1892 to be
precise, a biscuit company was started in a nondescript house in Calcutta (now Kolkata) with an initial
investment of Rs. 295. The company we all know as Britannia today.

The beginnings might have been humble-the dreams were anything but. By 1910, with the advent of electricity,
Britannia mechanized its operations, and in 1921, it became the first company east of the Suez Canal to use
imported gas ovens. Britannia's business was flourishing. But, more importantly, Britannia was acquiring a
reputation for quality and value. As a result, during the tragic World War II, the Government reposed its trust in
Britannia by contracting it to supply large quantities of "service biscuits" to the armed forces.  As time moved
on, the biscuit market continued to grow and Britannia grew along with it. In 1975, the Britannia Biscuit
Company took over the distribution of biscuits from Parry's who till now distributed Britannia biscuits in India.
In the subsequent public issue of 1978, Indian shareholding crossed 60%, firmly establishing the Indians of the
firm. The following year, Britannia Biscuit Company was re-christened Britannia Industries Limited (BIL).
Four years later in1983, it crossed the Rs. 100crores revenue mark. On the operations front, the company was
making equally dynamic strides. In1992, it celebrated its Platinum Jubilee.

In 1997, the company unveiled its new corporate identity - "Eat Healthy, Think Better - and made
its first foray into the dairy products market. In 1999, the "Britannia Khao, World Cup Jao" promotion further
fortified the affinity consumers had with 'Brand Britannia' Britannia strode into the 21st Century as one of
India's biggest brands and the pre-eminent food brand of the country. It was equally recognized for its
innovative approach to products and marketing: the Lagaan Match was voted India's most successful
promotional activity of the year 2001 while the delicious Britannia 50-50Maska-Chaska became India's most
successful product launch. In 2002, Britannia's New Business Division formed a joint venture with Fonterra, the
world's .

Second largest Dairy Company, and Britannia New Zealand Foods Pvt. Ltd. Was born.
In recognition of its vision and accelerating graph, Forbes Global rated Britannia 'One amongst the Top 200
Small Companies of the World', and The Economic Times pegged Britannia India's 2nd Most Trusted Brand.
Today, more than a century after those tentative first steps, Britannia's fairy tale is not only going strong but
blazing new standards, and that miniscule initial investment has grown by leaps and bounds to crores of rupees
in wealth for Britannia's shareholders.

BHAGWATI FOODS PVT. LTD.

Bhagwati Foods Pvt. Ltd. Sachendi Kanpur was established in 1 March 2007. Bhagwati Foods Pvt Ltd ,
Kanpur co-packer unit of Britannia industries Ltd. Mr. Hariom Gupta is the Director of the plant. Many types of
product made by Bhagwati foods ltd. Like as Butter cookies, Butter elaichi, Mariegold, Tiger glucose.

It located on Akbarpur Road about 25 km away from Kanpur city. The monthly Production of
Biscuits is 2278 Tones. The plant commenced production in March 2007.

At bhagwati foods pvt ltd has an effective manpower 176 which includes both line and staff
authorities. At Tigar plant is 3.23 tones per hour every day and Marie plant is 1.83 tones per hour
every day. the achievement of plat includes International Standard for Organisation (ISO).
 Use of ingredient and its role

Biscuits making ingredient can be classified two categories.

A. Major ingredient.

1. Wheat flour.

a) It is primary ingredient for baking.

b) Wheat flour used for biscuit making should be made from a soft wheat variety.
c) Protein content should be low.
d) The moisture absorption of flour to make a dough should not be more than 60%.
e) The flour should make dough with more extensibility but less resistance.
f) Development of gluten complex.

2. Refined Bleached Deodorised (RBD Palm oil).

a) It gives the sweating properly.

b) It gives the prow string through the aeration.

c) H.V.O. given the aeration in the dough.

d) It gives sytobit & given the crispynes.

3. Sugar.

a) Main function of sugar in biscuits to use as sweetness.

b) Sugar is set of rancidity control the shrinkage & spread.

c) It helps in enhancing the flavor of biscuits. & helps in retention of moisture.

d) It helps in providing colour; caramelization & maillard type browning. It acts as a

preservative also.

e) Less retention more water absorption power.

f) It gives to brown colour.

g) A part from this sugar maintains moisture of dough.

4. Invert Syrup.

Invert sugar syrup is pale colcured sweetener prepared by the acid hydrolysis/
enzymatic hydrolysis of a solution of white refined sugar. Inver syrup contains equal
proportions of the invert sugar glucose and fructose. It has wide application and is
particularly useful where high concentrations of invert sugars are fructose. The crystal-
inhibiting characteristics and humectants properties mean that the shelf life of many
products can be extended by the use of invert syrup in product formulations. It is an
equimolar mixture of glucose & Fructose. It is obtained by acid or enzymatic
hydrolysis of sucrose.

a) It gives the colour.

b) Maintain the dough PH.

c) Freezing point depressant.

d) Provide body and cohesiveness.

B. Minor ingredient.

1. Salt.
a) It is a flavour & taste enhancer.
b) It exerts desired strength & tightening effect on dough.
c) It is preservative & taste.
d) Hording of gluten.

2. SMBS.
a. Dough conditioner cut the long chain of gluten.
b. It gives the extensibility and elasticity.
c. It gives the extensibility power.
d. It cut the sit bond of gluten.
e. Increased the machine ability.
3. Skim milk powder.
a) Give the browning colour on top surface of area.
b) Taste of the final product.
c) Gives the protein.

4. Lecithin.
a) It natural antioxidant at con reduce.
b) It is emulsifier.

5. Citric Acid.
It is providing colour to syrup.

6. Sodium Bicarbonate.
a) It maintains the pH of final products.
b) To given the crumb colour (inner side of biscuits colour).
.
7. Ammonium Bicarbonate.
NH4CO3 - NH3I + CO2 + H2O
a) Expansion of volume.
b) It is help to maintain the dough ph (7.5-80).
c) It is aerating aren’t.

8. Sol bakes.
It is emulsifier and provides stability of product.
9. Ferrous Fume rate.
 Have more elemental iron in it.
10. Calcium Carbonate.
It is provide calcium to final product.
11. Flavour
a) It is used for unique flavour.

b) It enhances the taste.

 Laboratory
A. Testing of Raw material
1. Wheat Flour

a) Moisture

Take weight of
empty Petri dish

Take 10 ml sample
of maida

Pour in the perti

dish and again take
weight

Put the dish in oven

at 135°C for 1.5
hours /105°C for
half hour

Take out the petri

dish and again take
weight
 Dry Weight = (A-B)

Moistur %= Dry wt *100

Sample wt

b) Ash.

1. It gives the information the % of bran & foreign materials present in the flour.

2. Less moisture indicate more ash content.

3. Ash is a mineral content of the flour.

Principle:

1. Total ash is the inorganic residue remaining after incineration of sample.

2. It also indicates the grade or extraction rate of flour.

Apparatus:

 Silica dish, Balance, Muffle furhace, Dessicator etc.

Procedure:
Take the weight of crucible

Take 10 gm sample in
crucible

Put the crucible in muffle

furnace at 550°C +/_-30°C
for 4 hours

Cool it in dessicator for

30 mins

Now take weight of the

crucible

W1 * 10000 / W * 100 - M

Dry weight = (B-C)

c) Acid Insoluble Ash.

Principle:

1. It gives idea about added mineral matter dirt, sand etc.

2. It indicates the silica content. This is mainly due improper cleaning of wheat prior

to milling.

3. Higher quantities of acid insoluble ash are injurious to health.

Apparatus:-

Muffle furnace, water bath, dessicator.

Reagan: - 5N HCI

Procedure:-
Take the ash content in
crucible

Take 25 ml 5N HCL in it

Heat till bubbling

Fliter it with 42 no.

Whattman filter paper
 Check the pH time to time
and keep filtering and
washing till its acidic

Put the residue in muffle

furnace for 2-2.5 hours with
the crucible

Now cool it in dessicator

Now again take the weight of

crucible with ash

d) Alcoholic acidity

Flour which stored long time, under goes various types of deterioration, which in turn gives high
value for alcoholic acidity this is accelerated in presence of high moisture, temperature etc.

Principle:-

Alcoholic acidity to the combined acidity as we get by.

1. Hydrolysis of fat by Lipase in free fatty acid.

 2. Hydrolysis of protein in to amino acid by proteolysis enzymes.
3. Acidity due to presence of certain acid, salts etc.

Reagents:-

1. Neutral Ethyl Alcohol- 90% (volume).

2. STD, Sodium hydroxide solution.

3. Phenolphthalein indicator.

Procedure:-

Prepare 90% ethanol

(45ml ethanol + 5ml water)

Put 2 drop of phenopthalin in

the above flask

Pour 0.05N NaoH till pink

colour appears

Now add 8gm sample in the

flask

Keep the flask on magnetic

stirrer for 1 hour
 Now filter it with filter paper
no 1

Take 10 ml filterate and add

2-3 drops phenopthalin
indicator

Titratre it with 0.05N NaoH

till pink colour disappears

24.52 * N * T.V/ Sample

e) Sedimentation value

Principle:

This principle is based on more sedimentation value of flour, higher will be gluten content and

the flour will be more suitable for bakery product.

Take 3.2 gm sample and 50

ml water in measuring
cylinder
 Add 5-6 drops of
Bromophenol blue and
shake for 5 mins
Add lactic acid and again
shake for 5 mins

Add lactic acid and again

shake for 5 mins
Then leave it for
settlement for 5 mins

Then leave it for

settlement for 5 mins

Note the reading that is

called the sedimentation
value

Note the reading that is

called the sedimentation
F) Gluten value

Determination of Gluten:-

Gluten is a protein which develops the flour is mixed with water the gliadine and glutenin protein

forms the elastic structure called Gluten.

Principle

Gluten is the most important gives idea about the flour strength.

Procedure:-
 Take Paper weight

Take 25 gm sample
Make dough with the help
of 12ml water

Keep washing with water

till rubbery gluten forms

Dip the dough in 100 ml

Takesalt
the solution
weight offorpetri
1 hour
dish

Put the Gluten Sample in

the form of balls in the
petri dish

Put the dish in oven at

105°C for 4 hours

Now Again take weight

 Gluten = (B-A)

g) Mud test:-

Take 5ml
Sample in test
tube & add 5ml
CCl4

Leave for 5
mins and the
mud will
settle down

Can observe the

presence of Mud

2. RBD

A. TBHQ (Tertiary Butyl Hydroxy Quinone )

Take 5ml Sample in test

tube & add 5ml methanol to
it
 Hold the above for 5 mins
& then add dimethylamine

Pink colour formation

shows the presence of
B. Free Fatty acid TBHQ

STEP 1: Solvent Prep. 45 ml ethanol + 5ml water

in flask and add 2-3 drops
of phenopthalin

Pour 0.05 N NaOH

Solution till pink colour
appears

Pour 0.05N NaoH till pink

colour appears

Take 15-20 gm sample in

a flask, mix the above
STEP 2:- solvent an boil it

Add phenopthalin and

titrate it with 0.05N
NaOH
 Note the titration Value

28.2 *N*T.V/ Sample

wt

C. Peroxide Value

Take 2-5 gm sample in a flask

Prepare 3:2
Chloroform:Acidic acid
mixture

Take 30 ml from the above

mix in the sample flask

Pour 0.5 ml saturated KI

solution in the flask along
with 30 ml distilled water

Add 1% starch solution 1 ml

which serves as indicator
Calculation:
Titrate it with 0.01 N
thiosulphate

End point is disappearance

ogf blue colour

Note: along side prepare a

blank also.

1000 * S-B * N / wt of sample

D. Iodine Value

STEP 1 :- Preparation of the Solvent

 Potassium Iodate (KI) Solution:  100 ml water + 10 gm KI

(10 %)

 Starch Solution (1%)  100ml water + 1gm starch

STEP 2:

a) Starch solution is heated till it becomes transparent.

b) Palm Oil is heated till temp. Reaches 50-55°C.

STEP 3:

Take 0.2-0.5 gm sample of

palm oil

Take 25ml Wijs solution

(acetic acid + Glacial acid)

Now add 25ml CCL4 solution

to it

Close the flask with stopper

Add 10 % KI solution 1 ml
over the stopper of the flask so
that no oxidation takes place
from outside

Hold or keep it for half hour

Perform Iodine test with
washing water for judging

Iodine test must be Negative.

Titrate it with 0.1
N
Sodiumthiosulphat
 Step 4:-

Now add 100 ml

distilled water

Add 14 ml KI
solution

After it becomes
mango yellowish add
1ml starch solution
which acts as
indicator
Calculation:

B-S*12.69*N/
Sample wt

3 Condense Milk

Acidity

Take 5-7 gm
sample in a flask

Mix it in Luke
warm water 100ml
of 45°C & cool the
mixture
 Add 3-4 drops of
phenopthalin to it

Titrate it with
0.05N NaOH

Calculation:
9 * A * N \ sample wt

4. Butter

Acidity Acidity
Take 5-7 gm
sample in a flask

Mix it in Luke
warm water 100ml
of 45°C & cool the
mixture

Add 3-4 drops of

phenopthalin to it
 Titrate it with
0.05N NaOH

Calculation:-

9 * A * N \ sample wt

5. Flavour.

Specific Gravity.

Take the weight of specific

gravity bottle

Fill the sample in the

specific gravity bottle fully
and then press the stopper

Again take the weight of

gravity bottle
B.Testing of Packaging Materials
1. C.B Boxes:
 GSM (gram/m2)
 For gsm take 10cm2 sample and take its weight.
 Dimension (length, width & height)
 No. Of Flutes
 Flute Height
 Bursting strength
 Moisture

2. Laminates:
 GSM
 Dimension
 Sensory Evaluation of Laminate (Colour etc.)

3. HM bags/ Polybags:-
 GSM
 Dimension
 Total Ash

Calculation:
GSM of wrapper = Weight of sample/ length * width unit2

Count per kg = 1000 / gsm * Cut of length* width

4. Dimension:

length, width & height

5. Flute Height

 measured from 3 inch mark

 X metre multiplied by 0.396

Standards of different varieties of Britannia Biscuits

SNo. Variety Moisture % Total Ash A.I.A% Fat % Acidity%

%
1 Tiger 1.75 1.0 0.1% 13.30 0.1
Glucose
2 Tiger Crunch 1.75 1.0 0.1% 19.50 0.1
3 Good Day 1.75 1.0 0.1% 22.0 0.1
Butter
4 Good Day 1.75 1.0 0.1% 23.0 0.1
Cashew
5 Butter 1.50 1.0 0.1% 19.50 0.1
Elaichie
6 Butter 1.50 1.0 0.1% 22.0 0.1
Cookies
7 Marie Gold 1.0 1.0 0.1% 10.90 0.1

Mixing
A. Creaming Process of Marie
1. Lawn Sugar

 Add 63 kg Sugar & 31.5 Kg Water at Ambient Temp.

2. RBD Invert Syrup (80° brix)

 All the Above 3 come into Creamer through PLC.

 20 ltrs extra water is added at 28-29°C for tiger.
 All the Powder Ingredients like Salt, Sodium Bicarbonate, Ammonium
Bicarbonate, ferrous fumerate, Calcium carbonate, Vitamin Premix-7 are Added in
Standard Quantity.
 Add Whey Powder (2.7 kg + 3 ltrs Water)
 Add Lactose (300 gm + 3 ltrs Water)
 Whey Powder and lactose are added in water solution.
 Now add Solbake Paste.
 Add flavours
  Stirring in creamer of above all for 8 mins.
 Cream is ready for 2 Sack.
 Cream is transferred to the mixer.
 Maida is added to the Mixer.
 Add SMBS 10 % Solution. (4 kg SMBS + 40 ltrs. Water)
 Mix the all in mixer for 5-6 mins at 10 Rpm.
 Dough is Prepared.

3. Invert Syrup
(80° brix)

B. Creaming Process of Tiger Glucose

 RBD+ Sugar+Invert Syrup
 Transfer it to Creamer.
 Add 33 ltrs Processed Water (28-29°C)
 Now add all the Powdered Ingredients
 Now add liquid Glucose, M. Sugar, Solbake Paste, Lecithin Paste & Condendsed
Milk.
 Now Add Flavours.
 Keep it for Stirring for 8 mins.
 Hence cream is prepared for 1.5 sack.
 Prepared Cream is dumped into mixer.
 Now Maida is added to mixer.
 Then add folic acid and SMBS 10% solution.
 Start the mixer.
 Dough is prepared.

Biscuit Preparation Procedure Step By step: 2 sack standard:

1. Creaming

Sno. Marie Gold Parameters Standard amount Unit of

Measurement
(UOM)
1 Process dust 6 Kg
2 Flavour Fisl-AMMG 23 440 Ml
3 Fl. SBU 24 200 Ml
4 Sugar solution 94.5 Lt.
5 RBD Palm oil 34.5 Kg
6 Solbake Paste 4.5 Kg
7 Whey- Lactose Powder 9 Lt
8 Invert Syrup 10 Kg
9 Water 17 Lt
10 Mixing time 4 Mins
11 Salt 1.8 Kg
12 Sodium Bicarbonate 1.2 Kg
13 Ammonium Bicarbonate 3.6 Ml
14 Mixing time 3-4 Mins
15 Temp. °C °C

2. Mixing:

Sno. Parameters Standard UOM

Amount
1 Maida 254 Kg
2 Vitamin Blend 80 Gm
3 Potassium Iodate 0.24 Gm
4 Ferrous Fumerate 32 Gm
 5 Calcium Carbonate 200 Gm
6 Mixing Time 2 Min
7 Dough temp 34-36 °C
8 Standing Time 20-45 Min
9 SMBS solution 2200 Ml
10 Mixing Time 5-6 Min

3. Sheeting

S.no Parameters
1 Sheeter Recycle 12mm
2 Sheeter Fresh 18mm
3 Laminator Ggauge roll 1 & 2 16mm & 9 mm
4 Cutter
5 Layers Formation
6 Gauge Roll 1 & 2 14 & 7 mm
7 Gauge Roll 3 2mm
8 Relaxation time 6 sec
9 Temp Of milk spray
10 pH of Milk Spray- slightly acidic

4. Cutting

 Cutter Rpm
 Wet weight 14-15 pcs working side
 Wet weight 14-15 pcs non working side.
5. Baking
 Temperature of all seven zones
 Set, Top & Bottom

6. Baking time
7. No of biscuits: 37
8. Weight in gram: 201
9. Gauge in mm: 197
10. Count/kg: 184

Preparation of Solbake Paste

(S: R: W=1:1.5:2)

Take 30 kg Solbake powder

into mixer of temp rises 50-
60°C
Add 45 kg RBD + Add 50
kg Water.

Keep it for stirring for 15

mins.and then cool for 30
mins.

Now the Solbake is ready

to use.

Preparation of P. Iodate

500 ml Water + 12 gm P.
Iodate

Standard for above is 1ml

water + 0.24 gm P. Iodate

P. Iodate is Ready
 Use 10 ml With Flavour
AMMG-23

Preparation of Lecithin Paste

Take 135 ltrs. Palm Oil & heat

& then add 45 kg lecithin

Stir the above for 30 mins

Lecithin is now
Allow it toready
cool to be
used
 Preparation of Glucose

5Kg Glucose + 5 kg Water

Mix the Above Properly

Glucose is ready
Preparation of Condensed Milk Spray

Take 69 ltrs water & add 16

ltrs. Condensed Milk

Add 5.6 kg Invert Syrup to

above

Add 160 ml caramel Colour

&Milk Spray
add 80 is ready for
ml AMMG-23
16 batch
 Preparation of M. Sugar

59 Kg Sugar + 1 Kg
Flavour (Vanilla)

Hold the Above for 48

hours

M. Sugar Is Prepared
 Preparation of Folic Acid Solution:

 3.75 gm folic acid Solution + 5 ltrs Water

Function of Rotary

Application

The single head rotary cutter prints find design on a continuously fed dough on a continuously
fed dough sheet and also cuts out the individual dough piece.
Operation:-

The unit powered by 1.5kw helical geared motor and speed controlled by AC frequency
controller. Drive is given to cutting roller only to accommodate different sizes of die’s in this
machine.
Rubber lined anvil roller is adjustable in height so that pressure can be controlled at both sides in
parallel or independently. The anvil roll is being driven by friction of the cutting web which is
independently powered by its own separate drive. For safety reasons the cutting roll is provided
with guard removal of which stops the motor.
Rotary moulder:-

The dough to be moulded is fed into the hopper and a forcing roller forces the dough into the
moulding roller made out of gun metal, uniformly engraved and coated with food grade Teflon.
Excess dough is cleared with a knife, which is held by a holder made from tool steel, to ensure
uniform filling.

An adjustable rubber roller conveying the discharge web, presses it uniformly against the
moulding roller for perfect transfer of molded pieces from the moulding roller on to the web.
The purpose of three drives is, speed of the forcing roller influences the density of dough forced
in to the moulding cavity. The speed of the die roller influences the production speed. The
discharge web speed influences the shape of the biscuits produced along the web or across the

Function of Oven

The oven body consists:-

This is a multi zone indirect fired biscuit oven suitable for general purpose biscuit baking. This
oven is divded into a number of independent zones each comprising a combustion chamber with
burner, circulating fan, turbulence fan, and the associated duct work leading the banks of radiator
tubes

Radiant heating system:-

The products of combustion are recalcated through 102mm, dimeter tubes above and below the
band. The gases in the radiater tubes are negative pressure to ensure that the products of
combustion cannot contaminate the goods in the event of leakage. This system gives maximum
to atmosphere, the remainder to the combustion for re-heating.

Construction:-
The oven body consists of steel steamtight tunnel with appropriate divided zones along with
heating chambers and stainless steel expansion joints are provided in order to eliminate the
expansion of the oven sections. The inspection windows are provided for inspection of the
baking goods during the process.

Heating Chambers:-
The complete chambers will be insulted from outside and fully automatic oil/gas burners shall be
fitted to produce required heat and temp shall be controlled by automatic temp control fitted to
the main control panel. The dynamic balanced stainless steel fans/ blowers are provided to re-
circulate the heat and to increase the efficiency to the plant with the help of appropriate electric
motors.

Baking System:-

The baking takes place by heat radiators located under and above the wire mesh band. The
closed circulation system having slight vacuum so that the combustion gases cannot enter into
the baking zone. The moisture inside the baking zone should be controlled by separately by
another blower having proper damper damper controller .

Insulation:-

The complete oven will be covered with 8” or 10” thick mineral wool from top, bottom and the
sides to preserve heat loss.

Dive & conveyor band:-

Appropriate A. C or Dyno D. C Drive is being fitted to drive the Z- 47 articulate wire mesh bond
on two rollers provided on not end of baking oven.

Electrical:-

Auto – electric control panel is provided along with safety devices to operate all electric motors,
drives and also to control temperature to maintain required uniform heat at each baking zone
by thermostatically auto temp controller.

 Zone 1 & 2 are for Puffing

 Zone 3 & 4 are for Muffing

 Zone 5-7 are for Colouring

Damper Position Of Oven: Marie Gold TIGER GLUCOSE

Zone Damper Position

Zone Damper Position
1 Closed
1 25%Open
2 25%open
2 50%open
3 50 % Open
3 75 % Open
4 75 % open
4 100 % open
5 100 % open
5 100 % open
6 100 % open
6 100 % open
7 100 % open
7 100 % open

Cooling conveyor

From oven delivery the product is taken in to a series of conveys where It & losses the
last traces of moisture. The product is usually turned over & black again during its journey to
ensure even cooling throughout & the total process takes one & a half times the oven bake
time.
Total Cooling time is 03.60.1.

Construction

Cooling conveyor is made in a modular construction of 2.5 metres. Long and connected
together to form the required length .the supporting side channels are fabricated from 3mm
thick M.S. sheet .

Idle rollers are spaced at 750mm apart on conveying direction and 1700mm on the return
direction. All the idle rollers are of 48mm.
Dia, mounted on 6004 ZZ deep groove ball bearings with grinding finish and hard chrome plated
for hygienic conditions.As you know very well practically about the dropping of oil from the
cloth due to rudding of cloth against tie angles when when producing high fat biscuits. To
minimise this we replaced the all tie angles also with idle rollers. This might costs littie extra, but
you can maintain hygienic conditions at woring area. Drive drums are tswo no’s of 22mm dia
and projections are made on the surface of drums to minimise slip or covered with friction grip
rubber tape. Manual tensioning and tracking are provided.You can rely only on feeder table to
stack the oil sprayed biscuits which does not require more travel after oil spraying.

Stacking Machine

Packaging

Packaging is done in following criteria’s -

 Packages should protect & preserve the product that is attractive enough’ to catch
the eye & that describes the product adequately.
  Packages not to shake about during transit causing breakage.
 Packages need to be airtight .to stop the product taking up moisture from the
atmosphere & become soft.
 The Package give consumer information & about ingredients
 It should also indicate, when the product must be used by & give some nutritional
information about the product as wel.

SETTING OF CROSS PUSHER

 This adjustment is carried out with jaws hot (about 180*cTemp ) and knife
(cutter) removed.

 Never remove the anvil from the lower jaw. It is accurately set in our factory.
  Tighten the screw F lower jaw.
 Position the crimp jaw in tangency.
 The lower crimp jaw is fixed .all adjustment are to be made on the upper jaw.

CROSS PUSHER’S INITIAL POSITION

The initial position of cross pusher should be such that gap A between cross pusher and
adjustabil guide will be 2 to 3 mm. and gap b will be 1 to 2 mm. adjust the gap between
guide equals width of the biscuit+3mm.

CROSS PUSHER’S FINAL POSITION

The final position of cross pusher should be such that feeding conveyor rod should be
able to carry the product and also product should not foul with front rod.

CUT OFF LENGTH ADJUSTMENT

This adjustment serves to feed more or less material during the machine cycle.
depending on the length of the product to be wrapped.
 Adjustment to be carried out during machine running and all rollers in open
condition.
 To decrease cut off length turn knob in clockwise direction.
 To increase cut off length turn knob in anti-clockwise direction.
 Turn the knob till PKL meter shows the values given.

To control on broken generation.

Broken generation play a very important Role in biscuits industries. More broken generation
means less production. Recycle of broken generation involves.

 Wastage of electric.
  Wastage of money.
 Wastage of man power.
 Wastage of time.

Full process of Biscuits making

For each variety of Biscuits a specific mixing sequence and procedure are adopted. Various
chemical reactions involved, and final dough characteristics required are considered before
formulation of mixer operations procedure. Different type of mixer with different blade
configurations and variable motor are used. Proper mixer as well as proper mixing plays a vital
in biscuit making. That is why it is said that mixing, it “ Heart of biscuits making there are type
of mixers generally used for mixing purposes.

 Horizontal mixer.

 Vertical spindle mixer.

PROCESS FLOW DIGRAM OF BISCUIT MANUFACTURING

(TIGER)
- ALL CCPs Marked in RED.

Condense Milk + Soya Lecithin

+ Chemicals+ *Invert Syrup
 Usable Sugar Flour

Biscuit

Sorting Grinding Magnet

Tray

* (Invert Syrup)
Not OK
Magnet Sieving
Metal
Detect
or

OK Reject material
Sieving
Grinding

Sieving

Magnet
Biscuit Dust Premixing

Mixing
Dough Re Used

Dough Hoper

Dough Crasher

Dough In Catch Trays Metal NOT OK

Detect
or

OK Rejected
 Moulder
Waste Dough

Panner web

Oven (1to7) Rejected

Cooling Conveyor

Metal
Detect
or

Not OK
Stacker

OK

Packaging Rejected

FG store

Sieve Standards

Sno. Name Of the Ingredients Mesh No Of the sieve

1 Wheat flour/Starch/Rice Flour 40 mesh (min 24)
2 Whole Wheat Flour 30 Mesh (24)
3 Suji (Rava) 16 mesh
4 Toasted Ragi / Soya Flour 24 Mesh
5 Invert Syrup 40 mesh
6 Chemicals During Mixing 16 mesh
7 Process Dust broken Low fat Varieties-16 mesh
High Fat varieties- 12 mesh
8 Palm Oil 60 mesh (min 24)
9 Butter 24 mesh
10 Liquid Glucose 60 mesh (when Dissolved in water)
11 Liquid Glucose Min. 16 mesh (Direct Sieving)
12 GMS Powder 24 mesh
13 Lecithin Fat 24 mesh
14 Colour Solution, Flavour, Citric acid 100 mesh (min 60 mesh)
Potassium Iodate, SMBS
15 Condensed Milk 40 mesh (if dissolved in water)
24 mesh (if directly sieved)
16 Honey 24 mesh
17 Inactive yeast Powder 24 Mesh
18 Malt Extract, Apple Juice Concentrate 16 mesh
19 Cocoa Powder 16 mesh
20 Skimmed milk Powder, Coconut Milk Powder 40 Mesh (for solution)
24 mesh (for direct sieve)
21 White Choclate,Compound Choclate,Cocoa mass 100 mesh
22 Water 100 mesh
23 Other Chemicals 24 mesh

Daily Quality Index-DQI

CBB

1. CBB coding
 2. CBB Taping
3. Head Space
4. CBB Busting
5. VBB Liners

Pouch Quality

 Pouch Tightness
 Sealing
 Burst/Tear

DQI

 Pack Weight
 Pack Tightness
 Pack Coding
 Pack Seal
 Broken

Product Quality

 Colour
 Dimension
 Flavour/taste
 Bite
 Appearance

Daily assignment on oven section

Date 07-07-12 Baking time 03.34.5 RPM 28rpm

 Tiger  
Zone 1 2 3 4 5 6 7
Set 200 270 280 320 280 260 225
Actual 200 257 270 302 265 245 177
Top 209 269 284 311 276 255 196
Bottem 179 200 236 313 261 254 182
 100  100  100  100
Demper Opan  25%  50%  75 % % % % %
   
Inderint temp Creaming Time  8 Min  
Syrup  39.3c Mixing Time  6 Min  
RBD  36.2c  
Process water 24.8 c           

Date09-07-12 Baking time 03-21-8 RPM 30rpm

 Tiger  
Zone 1 2 3 4 5 6 7
Set 200 270 280 320 280 260 225
Actual 200 257 270 302 265 245 177
Top 209 269 284 311 276 255 196
Bottem 179 200 236 313 261 254 182
 100  100  100  100
Demper Open  25%  50%  75 % % % % %
   
Inderint temp Creaming Time  8 Min  
Syrup  40.9c Mixing Time  6 Min  
RBD  43.5c    
Process water  24.7c          

Date 12-07-12 Baking time07:22:7 RPM 15.50

Cookies  
Zone 1 2 3 4 5 6 7
Set 150 220 225 255 130 205 180
Actual 148 222 225 253 190 202 155
Top 158 233 240 264 201 213 178
Bottem 139 181 204 265 299 215 159
 100  100  100  100
Demper Opan  25%  50%  75 % % % % %
   
Inderint temp Creaming Time  8 Min  
Syrup  38.2c Mixing Time 6 min  
RBD  40.3c    
Process water  25.3c          

Date 13-07-12 Baking time 03:22:3 RPM 49rpm

 Marie Gold  
Zone 1 2 3 4 5 6 7
Set 197 240 290 300 280 270 250

Top 197 216 293 301 280 271 248

Bottem 255 288 233 261 258 302 282
 100  100  100  100
Demper Open  25%  50%  75 % % % % %
   
Inderint temp Creaming Time  8 Min  
Syrup  41.8c Mixing Time  6 Min  
RBD  45.6c    
Process water  24.8c          

Date 16-07-12 Baking time 03:44:2 RPM 50rpm

 Marie Gold  
Zone 1 2 3 4 5 6 7
Set 197 253 290 300 280 303 304

Top 190 235 281 295 274 265 258

Bottem 239 289 235 264 259 301 283
 100  100  100  100
Demper Open  25%  50%  75 % % % % %
   
Inderint temp Creaming Time 8  min  
Syrup  37.5c Mixing Time  6 min  
RBD  43.5c    
Process water  25.6c          

Date 17-07-12 Baking time 03:42:3 RPM 51rpm

 Marie Gold  
Zone 1 2 3 4 5 6 7
Set 197 253 290 300 280 260 240

Top 197 222 294 301 279 268 244

Bottem 251 292 239 266 259 303 271
 100  100  100  100
Demper Open  25%  50%  75 % % % % %
   
Inderint temp Creaming Time  8 Min  
Syrup  40.8c Mixing Time  6 Min  
RBD  44.6c    
Process water  23.8c          

Daily Assignment on Packaging Section

Date 25/07/12
Variety Weight Number Of Biscuit Rs.
Tiger Glucose 1
 1 33gr 8 2/-
2 45.5gr 11 3/-
3 62.5gr 15 4/-
4 79gr 19 5/-
5 150gr 36 10/-
6 300gr 72 20/-
Marie
Gold
1     64gr   12     5/-
2     122.5gr   22     10/-
3     170.5gr   31     15/-
4     337gr   63     28/-
Cookies
1 Butter     50gr   10     5/-
Elaichi     50gr   10     5/-

Date 26/07/2012

Temperature
Ferrari-1
No. RL1 RL2 UJ1 UJ2 LJ1 LJ2 LS .
pv 139 139 137 135 136 136 140 ppm
sv 140 140 140 140 140 140 140 142

Ferrari-2
No. RL1 RL2 UJ1 UJ2 LJ1 LJ2 LS .
pv 157 160 140 139 136 145 46 ppm
sv 160 160 140 140 140 145 140 140

Ferrari-3
NO. RL1 RL2 UJ1 UJ2 LJ1 LJ2 LS .
pv 157 160 140 139 139 145 46 ppm
sv 160 160 140 140 140 145 140 128

Ferrari-4
No. RL1 RL2 UJ1 UJ2 LJ1 LJ2 LS .
pv 167 159 146 144 142 143 68 ppm
sv 165 160 147 147 148 148 65 144

Ferrari-5
NO. RL1 RL2 UJ1 UJ2 LJ1 LJ2 LS .
pv 186 184 143 139 138 139 87 ppm
sv 186 185 151 142 142 142 86 132

Ferrari-6
No. RL1 RL2 UJ1 UJ2 LJ1 LJ2 LS .
pv 164 142 144 147 145 147 81 ppm
sv 165 170 145 146 145 144 78 128

Date 27/07/2012
Ferrari-1
NO. RL1 RL2 UJ1 UJ2 LJ1 LJ2 LS .
pv 149 150 140 132 138 137 83 ppm
sv 150 150 138 138 140 140 80 134

Ferrari-2
No. RL1 RL2 UJ1 UJ2 LJ1 LJ2 LS .
pv 158 160 138 140 138 145 43 ppm
sv 160 160 140 140 140 145 140 140

Ferrari-3
NO. RL1 RL2 UJ1 UJ2 LJ1 LJ2 LS .
pv 161 162 136 133 134 128 129 ppm
sv 160 165 137 137 136 127 130 140

Ferrari-4
No. RL1 RL2 UJ1 UJ2 LJ1 LJ2 LS .
pv 165 160 146 143 139 142 68 ppm
sv 165 160 147 147 145 145 65 136

Ferrari-5 ppm-114
No. RL1 RL2 UJ1 UJ2 LJ1 LJ2 LS .
pv 185 184 134 138 142 140 86 ppm
sv 186 185 140 142 142 142 83 114

Ferrari-6
NO RL1 RL2 UJ1 UJ2 LJ1 LJ2 LS .
pv 164 137 134 140 135 140 81 ppm
sv 165 170 135 140 135 144 78 112
Bhatt-1
RL1   RL2   UJ/LJ ppm
138   136   120 82

Bhatt-2 ppm-80
RL1   RL2   UJ/LJ ppm
154   149   117 80

CONCLUSION
 During the training period I learnt a lot & the training concrete shape to my little
knowledge about biscuit manufacture. I gained a lot in terms of practical knowledge about the
problems faced in the industry.

In Bhagwati Foods Pvt. Ltd. Company, the major emphasis is on the quality ‘of raw
materials, finished product. The raw materials greatly influence the quality of finished product.
In order to ensure that the raw materials used in production are of good quality the company has
laid down a set of specification for each of them. The standardization & revision of raw materials
specifications are done time to time.

I have also learnt to work in a team in coordination with others the training, has a big impact on
my perception about the working of an industry.

References

 Mr. Vinod Dwivedi (Production Manager, Britannia industry Ltd.)

  Mr. Gaurav Chaturvedi (Quality Officer, Britannia industry Ltd.)

 Mr. L M Jhosi (Factory Manager, Bhagwati Foods Pvt Ltd)

 Mr. Prashant Singh Sachan (Quality Manager Bhagwati Foods Pvt. Ltd.)

 Mr. Rajesh Chauhan (Lab Incharge, Bhagwati Foods Pvt. Ltd.)

 Mr. Sanjay Sharma ( Food Safety Team Leader, Bhagwati Foods Pvt. Ltd.)

 Mr. Sumit Verma ( Lab Chemist, Bhagwati Foods Pvt. Ltd.)

Web Site link

 Www. Google. com

 Www. Wheatflour.com
 Www. Biscuit.com

Sachan.prashant@gmail.com