LEARNINGS AT DISHA FOODS LTD.

Submitted byVikas Kamboj ( In-plant trainee) Category- Biscuit Manufacturing Disha Foods Pvt. Ltd. Hyderabad

The ITC Vision & Mission

Sustain ITC's position as one of India's most valuable corporations through world class performance, creating growing value for the Indian economy and the Companys stakeholders

To enhance the wealth generating capability of the enterprise in a globalizing environment, delivering superior and sustainable stakeholder value

Awards & Accolades

ITC Chairman Mr. Y C Deveshwar conferred the Padma Bhushan. One of the foremost in the private sector in terms of : Sustained value creation (BT-Stern Stewart survey) Operating profits Cash Profits Ranks No. 3 among Indian listed Private Sector Companies by market cap. No. 1 in FMCG Sector Only Indian FMCG Company to feature in Forbes 2000 List A comprehensive ranking of worlds biggest companies measured by a composite of sales, profits, assets & market value Rated as one of Indias Most Respected Companies (IMRB-Business world Survey 2006)

Key Corporate Strategies

Focus on the chosen business portfolio FMCG; Hotels; Paper, Paperboards & Packaging; Agri Business, Information Technology Blend diverse core competencies residing in various businesses to enhance the competitive power of the portfolio Position each business to attain leadership on the strength of world class standards in quality and costs Leverage the goodwill of trademarks to: Capture emerging opportunities Further enhance current brand equity

Craft appropriate strategy of organization and governance process to : Enable focus on each business and Harness diversity of portfolio to create unique sources of competitive advantage

Social Impact
Direct employment ITC Group : 29,000 Indirect employment across the value chain : 5 million e- choupal: worlds largest rural digital infrastructure serving nearly 4 million farmers Social and Farm forestry initiative has greened over 125,000 hectares & provided approx. 51 million person-days of employment among tribals & marginal farmers Significant thrust on social sector investments Natural resource management Sustainable livelihoods Community development programmes in the economic vicinity of

FOODS DIVISION

ITC made its entry into the branded & packaged Foods business in August 2001 with the launch of the Kitchens of India brand. A more broad-based entry has been made since June 2002 with brand launches in the Confectionery, Staples and Snack Foods segments. The Foods business is today represented in 4 categories in the market. These are: Ready To Eat Foods Staples Confectionery Snack Foods

Sunfeast In July 2003, ITC forayed into the Biscuits market with the Sunfeast range of Glucose, Marie and Cream Biscuits. In a span of 9 years, Sunfeast has well-established presence in almost all categories of biscuits. Biscuit Manufacturing at ITC has seen a tremendous growth in terms of sales revenue generated and demand in the market. ITC has a large number of CMUs (contract manufacturing units) on profit sharing basis all over India for growing demand for its biscuits.

DISHA FOODS Pvt. Ltd.

Disha foods Pvt. Ltd. is a CMU for ITC FOODS Ltd. Located at Industrial area, Kattedan, Plot no.82, Hyderabad, Andhra Pradesh.
Agreement between ITC and Disha foods materialized in 2007, before that only domestic production took place at the plant. Mainly 2 varieties of Biscuits are produced at this plant, namely : 1) Glucose Biscuits SKU- 28+4gm, 40gm , 60gm , 75gm, 150gm , 300gm 2) Special Cream Biscuits : a) Choco

b) Orange

c) Elaichi

SKU- 5ogm , 100gm

PLANT LAYOUT

FIRST FLOOR

SECOND FLOOR

WATER SYSTEM IN PLANT

Role of ITC at CMU

To ensure : Maintaining Quality, Reduction in operational cost, Implementation of ITC norms, Proper distribution of finished Goods, Take care of ITC assets ITC has placed its team having 3ME, 1JTA, 1FE, 1Team Leader

BISCUIT
A biscuit is a baked, edible, and commonly flourbased food-product. The middle French word bescuit is derived from the Latin words bis (twice) and coquere, coctus (to cook, cooked), and, hence, means "twice-cooked. This is because biscuits were originally cooked in a twofold process: first baked, and then dried out in a slow oven. Biscuits today are of many different shapes and sizes, but most are small at around 2 inches (5.1 cm) in diameter, and flat. The term biscuit also applies to sandwich-type biscuits, wherein a layer of cream or icing is sandwiched between two biscuits India is a leading player in biscuit manufacture hovering just after USA and China.

RAW MATERIALS
FOR SUNFEAST BISCUITS- (kg per Batch) Maida Sugar RBD Palm Oil Invert Syrup Lecithin Liquid Glucose Skimmed Milk Product Salt Sodium Bicarbonate Ammonium Bicarbonate Colour solution Flavour Mix Sodium Meta Bi Sulphide Biscuit Dust Sodium Acid Pyro Phosphate

FOR CREAM PREPARATION

Ingredients of Orange CreamRBD Palm Oil Sugar Powder Skimmed Milk ProductMaize StarchLecithinOrange Juice PowderColour SolutionFlavour MixCitric acid(kg per batch) 90 236.249 3.214 1.799 2.249 0.143 1.170 2.024 0.514

Ingredients of Choco Cream- (kg per batch)

RBD Palm OilSugar Powder Choco PowderSkimmed Milk ProductMaize StarchLecithin90 228.190 8.057 3.193 1.277 2.233 2.210

Flavour Mix-

INGREDIENTS FOR ELAICHI CREAM(kg per batch) RBD Palm Oil Sugar Powder Skimmed Milk ProductMaize StarchLecithinColour SolutionFlavour Mix90 221.249 1.500 7.499 3.003 0.410 2.246

Cream preparation procedure

R.B.D palm oil, lecithin , SMP , maize starch are taken in the mixer pan. (orange juice powder and citric acid is added in case of orange cream) Mixing done for almost 5 min. Then sugar is added from top section after weighing in sugar grinder section. ( cocoa powder is added in case of choco cream) Again mixing is done for almost 5 min. Then flavor and colour are added and mixed again for approximately 5 min till desired consistency of cream is obtained.

INGREDIENTS

GLUCOSE

ORANGE

CHOCO

ELAICHI

MAIDA
SUGAR PALM OIL INVERT SYRUP LECITHIN L.GLUCOSE SALT ABC COLOUR SOL. SAPP BISCUIT DUST SMP SMBS

250
83.333 47.123 17.857 0.446 1.984 2.48 AS REQ. 0.650 0.764 25 2.976 0.050MAX

300
110 55.714 8.571 0.571 2.786 1.357 AS REQ. 0.837 0.357 0.143 30 -

300
98.857 55.714 8.571 0.571 CARAMEL3.786 2.757 1.429 AS REQ. 0.651 0.651 0.714 30 -

300
110 55.714 8.517 0.571 2.786 1.357 AS REQ. N.M N.M 0.143 30 0.050MAX

BAKING SODA 1.488

FLAVOUR MIX 0.650

Variables in the Process

ABC Water Mixing time Water temperature SMBS(for elaichi and glucose only)

Major Ingredients in Biscuits

Maida Made by grinding clean conditioned , soft or hard wheat or blends in a flourmill. Main constituent in most Biscuits. The Protein from Maida forms a sticky rubbery mass when combined with water. This is known as Gluten which provides the basic framework. Gluten permits the retention of gas bubbles during baking of a Dough to give open textured & pleasant eating products. It consists of almost 60-65% of mass in Biscuit. Maida has 2 proteins which combine to make Gluten.

RBD Palm Oil

Stands for Refined Bleached and Deodorized Palm Oil. Obtained from raw palm oil after subjecting the oil to the process of neutralization with alkali, bleaching with fullers earth or activated carbon or both and finally by steam odourization under vacuum. Gives texture, flavour , softness to the bite, shape, act as a shortening agent.

SMP
SMP is rich in lactose and proteins. These proteins in the SMP takes part in the Maillard reaction to give subtle flavor and textural improvement. Maillard reaction takes place between proteins and reducing sugars(invert syrup) at a certain temp. which gives a desired brownish colour to the biscuit. Maillard reaction occurs much faster in alkaline conditions It imparts flavour and colour to the biscuit.

Liquid Glucose
Prepared by controlled acid hydrolysis of starch. Refined and concentrated non-crystalline aqueous solution of d-glucose , maltose and other polymers of d-glucose. Viscous and transparent syrup with yellowish tinge.

SUGAR
Sucrose(sugar) is basic sweetener for the baking industry, it is derived from either sugar cane or sugar beet. There are different grades for sugar which need to be kept in mind before purchasing ,e.g. in our plant S-30 grade sugar is used. It acts as a bulking agent in biscuits. Has humectant properties which prevent baked products from drying out. Also acts as a colouring agent as well as preservative in some foods. It also has some effect on product spread as coarse sugar dissolves slower during baking, hence provides more structural support and therefore less spread of the product.

INVERT SYRUP
Invert syrup is a mixture of equal parts of fructose and glucose which is produced by the inversion of sugar. E.g. 65-67% sucrose solution is placed in a kettle and about 1.25% of citric acid is added, heat is then turned on and temp. brought to 107^C ( Boiling point of syrup) and held at this temp. for about 30 mins and then cooled to 38^C. Generally, a syrup having a pH of 2.5 and a moisture content of 22-23% is obtained. Another method of producing invert sugar is using the enzyme invertase, in which sucrose solution to which invertase is added is stored at room temp. for 7 days. At the end of this period the solution is converted to invert sugar solution. Invert syrup:- (in plant process) Heat water in tank up-to 85 to 900c then add sugar. Heat the mixture with constant stirring up-to 1050c. Add citric acid by dissolving in water. Stop heating when temp rise up-to 1100c. Cool the syrup upto 75-800c with continue stirring. Pass the syrup through magnet and sieve and store in a tank. The color of the syrup should be golden yellow to golden brown, brix should be 80-820 ,taste should be sweet & pleasant.

MINOR INGREDIENTS
ABC:- Act as a leavening agent. SAPP:- Balances the alkaline reaction of soda during baking in final zones. SMBS:- It is a dough improver, it breaks the gluten to soften the dough to get the desire product. Water:- helps to Forms gluten with the wheat flour, act as a puffing agent. Emulsifier(Lecithin):- Help water and oil to form an emulsion, softening the texture, reduces hardness by interrupting the gluten structure in the dough. By using small amount of emulsifier, the fat phrase is spread uniformly over the hydrophilic ingredients such as flour , sugar , etc. Salt:- Gives taste, surface dresser and helps in releasing the flavour. Citric acid:- It provide the acidic media for inversion Baking soda- Also acts as a leavening agent and prevents biscuit from collapsing after it has risen.

Material

Sampling for <200 10 bagsraw material norms of for >201 14 high Maida 6 bags
Maize starch Orange juice powder 5 bags for >100 2 bags per batch 7 bags for >101 6 high -

Sampling norms

Stacking norm for storage

R.B.D palm oil

Soya lecithin ABC Baking soda SAPP Sugar L.Glucose Salt SMP Cocoa powder SMBS Citric acid

from each compartment

3 bags for <50 4 bags for< 200 4 bags for<200 3 bags for< 50 6 bags for < 200 3 barrel for<100 3 bags for<50 6 bags for<200 6 bags for<200 3 bags for <50 2 bags per batch

4 bags for >51 5 bags for >201 5 bags for >201 4 bags for>51 10 bags for >201 5 Barrel for>101 4 bags for>51 10 bags for>201 10 bags for>201 4 bags for >51 -

Prefferably 1 , max2 12high 12high 12high 12high 12high 15high 10high 12high 10high

SAMPLING NORMS FOR PACKAGING MATERIALS

Packing Materials Wrapper Sampling Norms 5 rolls for <100 10 rolls for >101 Stack height for storage 8 high

C.F.C

10 cfc sample from 10 diff. bundles

250 gms approx. from 5 diff. bags

30high for 10 cfc bd 15high for 20 cfc bd 12high for 25 cfc bd

6 high

HM polybag

Trays
Slip Sheet BOPP Tape

10 trays for 5 boxes

10 pieces from diff. packs

9 high
8 high

10 rolls from 10 diff. boxes

Maida Sugar Palm oil

Moisture, LAB ANALYSIS purity, so2, water insol. Matter

m.c, total ash, aia, sedimentation va alc. Content, gluten content.

Iodine,peroxide,sap. Values, moisture,ffa ,acid value, slip point, unsap. Matter, TBHQ m.c, tit. Acidity, protein & non p. content, ash, fat, solubility.

SMP Cocoa powder L.Glucose Salt

Moisture, fat, ash, aia, alkalinity ash Purity, m.c, water insol. Matter

pH, purity, so2, total ash, total solid

Baking soda ABC

SMBS SAPP Citric acid Orange juice powder Maize starch

pH, purity, water insol. Matter Purity, nonvolatile residue.

Purity, pH, water insol. Matter pH, purity, loss on drying, water ins Matter Moisture, purity m.c, pH, total ash, D.E m.c, ash, aia, alc. Acidity

MAIDA SECTION

MANUFACTURING PROCESS
Chemical pre mixing area-

FLOW CHART FOR CREAMER

MANUFACTURING PROCESS

ROTARY MOULDER

FORCING ROLLER AND DIE

DOUGH BLADES AND DIE

Tools for handling dough

Zone
Zone 1&2

Process

BAKING PROCESS

Melting of fats and spreading across the biscuits structure Steam generation, Reaction of steam with ammonium bicarbonate and release of ammonia

Zone 3& 4

Steam reacts with starch causing starch gelatinisation (forms gel like structure)

It becomes hard after the oven.

zone 5&6 The protein denaturation take place.

Colouring of the biscuit starts called as browning reaction or Maillard reaction.

Amino acid + reducing sugar(acidic medium at <150 0c) caramelisation of sugar take place with brown colour.

Starch gelatinization
Starch gelatinization is a process that breaks down the intermolecular bonds of starch molecules in the presence of water and heat, allowing the hydrogen bonding sites to engage more water. This irreversibly dissolves the starch granule. Penetration of water increases randomness in the general granule structure and decreases the number and size of crystalline regions. The gelatinization temperature of starch depends upon plant type and the amount of water present, pH, types and concentration of salt, sugar, fat and protein in the recipe, as well as derivatisation technology used. Some type of unmodified native starches start swelling at 55 C, other types at 85 C. The gelatinization temperature depends on the degree of cross-linking of the amylopectin. Water is first absorbed in the amorphous space of starch, which leads to a swelling phenomenon during heating and then transmitted through connecting molecules to crystalline regions.

Lines & their capacities

Line 1 produces Special cream biscuits and has ideal capacity of producing biscuits at 2.247 tons per hour. Line 2 produces Glucose biscuits and has ideal capacity of producing biscuits 2.841 tons per hour.

Line 3 produces Glucose biscuits and has ideal capacity of producing biscuits 3.116 tons per hour.

Physiochemical Parameters of special Cream Shell

Diameter: Stack Length:sandwiches) Cream Application: Moisture: Acid Insoluble Ash: Acidity of Extracted Fat:43 1mm 114 3(9 25 2% 1.5% max 0.05% max 1.20% max

Physiochemical Parameters of Sunfeast glucose biscuits

Length: Width: Stack Length:biscuits) Moisture : Acid Insoluble Ash: Acidity of Extracted Fat:52 1 mm 32.5 1 mm 107 3mm (16 2% max 0.05% max 1.20% max

HACCP 7 Principles
1. Identify hazards 2. Determine Critical Control Points (CCPs) 3. Determine critical limits for CCPs 4. Monitor CCPs 5. Corrective action 6. Record data 7. Verify that the system is working.

HACCP AND GMP

HACCP is the program that is used in the food industry for FOOD SAFETY, not food quality. The goal of HACCP is to prevent and/or minimize risks associated with biological, chemical, and physical hazards to acceptable levels. It is based on PREVENTION rather than detection of hazards GMP(Good manufacturing practices) GMP means to obey and follow every rules and regulation made by the authority. It means run the plant as per SOP, maintain the plant hygiene, work environment and manufacturing safe food.

CRITICAL CONTROL POINTS

1) Sieving of raw materials before using for physical hazards. For Maida, SAPP, SMBS, soda, SMP etc mesh size is 32 & 40. For biscuit dust, ABC, mesh size is 18. 2) Metal detector for physical hazards. In dry area it can detect 1mm Fe & 1.5mm non Fe. Frequency of its check list is in every 2 hr. 3) 4th Zone oven temperature for biological hazards. Temp limit in this zone Is 245-3350c for Salmonella microbe.

PACKING SECTION
PACKING MACHINE COMPONENTS

Sandwich machine components

WRAPPER FEEDING DIAGRAM

Packing machine changeover

Finished product analysis

Moisture Acid insoluble ash Acidity of extracted fat No of biscuit in packet Net weight Stack height Biscuit dimension Color Shape & form Appearance Texture Taste & aroma Cream application (only for cream biscuit) Adhesion of cream and shell

Finished product analysis ( packing)

Secondary packing HMHDPE bag sealing No of packets in arrangement Physical condition pack date & batch code Tertiary packing CFC sealing Pack date & batch code Net weight of CFC No of packs Physical condition