INDUSTRIAL SUMMER INTERNSHIP PRESENTATION

Bikanervala Foods Pvt. Ltd., Greater Noida, Uttar Pradesh.

Submitted by-
Submitted to- Neeraj
Dr.Navnidhi Roll No.-200080830008
GJUS&T, Hisar.
B.Tech.(Food Tech.)4th year
 Content
• Introduction
• Processing in nutshell
• Production of Aloo Bhujia, Tasty and
Moong Dal
• Quality control and Assurance
• Packaging
• Conclusion
 INTRODUCTION
• Bikanervala is a brand of Indian sweets and namkeens.
• This brand started 115 years ago as a sweet and
namkeen shop called Lalji in Bikaner , Rajasthan.
• This brand has 94 stores including 25 stores abroad.
• In 1988, Mr. Shyam Sundar Agarwal launched Bikano to
sell sweets and namkeens in air tight packaging and also
to take the brand globally.
• There are several maufacturing plants in all over India
i.e. in Sonipat, Faridabad, Greater Noida, etc.
INDUSTRIAL TRAINING OBJECTIVES

• The purpose of industrial training is to

expose students to the world of work so
that they can relate theoritical knowledge
with application in industry. From the
industrial training the students will also
develop skills in work ethics,
communication , practical and theory.
 Greater Noida Plant
The Greater Noida plant of Bikanervala Foods Pvt. Ltd. (Bikano) deals only
with Namkeen’s and is divided into 2 units.

• UNIT I: Maximum operation done manually. It includes

5 fryers
6 Bhatti section (cookers for frying)
5 bhatti prepare SF
19 bhatti are for preparing traditional bikaneri bhujia .

• UNIT II: Most of the operations are done through machines and instruments. It
includes
4 fryers
These Fryers include:
– Aloo Lachha (Fryer 1)
– Aloo Bhujia/ Kurkuri Bhujia/ Aloo Bhujiya Lemon chaska (Fryer 2)
– Tasty/ Salted Peanut (Fryer 3)
– Moong Dal (Fryer 4)
Outline Process of Unit-2:
Raw material (RM)

Semi Finished Good(SFG)

Finished Good(FG)

Quality Check

Packaging

Dispatch
Products that are formed in unit 2

• ALOO LACCHA
• ALOO BHUJIA
• TASTY
• MOONG DAL
PRODUCTION OF ALOO BHUJIA
PRODUCTION OF TASTY
PRODUCTION OF MOONG DAL
 Types of fryer
Bikano has installed continuos fryer machineries and machineries and
equipment’s of Flavorite brand. These snacks processing and fryer
machines can handle manufacturing of ethnic Indian snack like Bhujia,
Sev, Lachha, Peanuts, and cornflakes. The fryers are of capacity
ranging from 250 kg/hr, 350 kg/hr, and 450 kg/hr to 1100kg/hr.

• Submerged fryer- Is a methid of frying by submerging food into oil at

high heat, typically between temperatures of 175 C to 190 C. Used
for Aloo Bhujia and Moong Dal.
• Heatwave fryer- Uses curtains of clean filtered oil instead of
submersion. The oil coats yout products, transferring heat quickly
and uniformly. Operate with dramatically lower oil volume than
conventional fryers. Rapid oil turnover rates produce snacks with a
fresh flavor and long shelf life. have various product conveyor and
infeed configurations. Used for Tasty ( batter coated peanuts)
Types of Aloo used for making Aloo Bhujiya and Lachha-
• LR- It is large in size and red in colour. Used for making lachha.
• Chipsona- It is small in size, yellowish in colour and are more dotted. Used
for making aloo bhujiya.

Selection of Raw materials for Bhujiya and Lachha-

On the basis of size-
• Aloo Bhujiya- small (as it needs to be boiled)
• Lachha- large (no need of boiling and also size of lachha has to be long)

On the basis of sugar-

• Aloo Bhujiya- ¼% sugar is acceptable
• Lachha- should be sugar free

On the basis of rottenness-

• Aloo Bhujiya- Acceptable upto some extent
• Lachha- no rotten potato should be choosen
 QUALITY DEPARTMENT
• The whole plant of Bikano runs entirely on oil, which is why it is
absolutely important that the oils being used are of the best possible
quality.
Bikano mainly uses three types of oils: -
Palmolein oil
Rice bran oil
Cottonseed oil
Out of these three oils only two oils are used at a time.
• To check the condition of oil we test samples of oils for
– Free fatty acids,
– Peroxidase value
– Oxidation value
– Iodine value
• Another thing that must be tested are the raw
materials as well as the finished goods. Each
product whether raw or finished must have some
factors in a particular range for that product to be
accepted. For raw and finished products, we test
the:-
– Salt percentage
– Acidity percentage
– Moisture content
– Stability
These tests are done on daily basis.
 Free Fatty Acids (FFA) in oil

To determine Free Fatty Acids (FFA) in oil:

• Take 45ml isopropyl alcohol and add 5ml of water.
• Neutralize this by using drops of Phenolphthalein Indicator and titrate with 0.1N NaOH
solution.
• A pink colour appears.
• Add 20gm of oil sample.
• Heat the solution at 90 degrees centigrade to check the end point of the result.
• Titrate the solution with 0.1n NaOH by using 3-4 drops of Phenolphthalein Indicator.
• Titrate until pink colour appears.

Formula: FFA= (2.82*T)/W

• T= titre value
• W= weight of sample Acid value
• = (2.82*T)/W
• STANDARD FFA VALUE OF OIL:
• PALMOLEIN OIL: 0.30
• RICEBRAN OIL: 0.50
• COTTON SEED OIL: 0.1
 PEROXIDE VALUE (PV) OF OIL
• Take 5gm of oil sample in stoppered iodine flask.
• Add 30ml of solvent mixture (Chloroform: Acetic Acid :: 2:3)
• Add 0.5ml of freshly prepared saturated KI.
• Hold for 1 minute in dark.
• Add 30ml of distilled water and mix gently.
• Add 0.5ml freshly prepared starch indicator.
• Titrate with 0.1N Sodium Thiosulphate
• Titrate it till milky colour appears.
Formula: PV= ((S-B)*N*1000)/W
S= titre value of sample
B= titre value of blank (0.012)
W= weight of sample
N= normality of sodium thiosulphate.

Standad PV= 10
 SALT % IN FINISHED
PRODUCT
• Take 2gm of crushed sample in a beaker.
• Now add 100ml of de-mineralized water.
• Keep the beaker on the magnetic stirrer for 5 minutes.
• Filter out the solution using a filter paper.
• Take 10ml of filtered solution in a beaker.
• Add 10ml of de-mineralized water into it.
• Now add 4-5 drops of Potassium Chromate.
• Now titrate this solution with 0.1 N Silver Nitrate.
• When red colour appears in the solution note down the reading.
• Formula: Salt%= (T*N*58.45)/W
• T= Titre Value
• N= Normality of Silver Nitrate
• W= weight of sample taken
• Salt% for AB- 3, Tasty- 2.5, MD- 1.6
 ACIDITY % IN FINISHED
PRODUCT
• Take 2gm of crushed sample in a beaker.
• Now add 100ml of de-mineralized water.
• Keep the beaker on the magnetic stirrer for 5 minutes.
• Filter out the solution using a filter paper.
• Take 10ml of filtered solution in a beaker.
• Add 10ml of de-mineralized water into it.
• Now add 4-5 drops of Phenolphthalein Indicator.
• Titrate the solution with 0.1N NaOH.
• The value is noted when pink colour appears in the solution.
• Formula: Acidity%= (T*N*64.03)/W
• T= Titre Value
• N= Normality of NaOH
• W= weight of sample taken
MOISTURE CONTENT OF FINISHED PRODUCT

• Take the sample and crush it with help

of mortar and pestle.
• Take 5gm of crushed sample in the
balance.
• Close the balance and press the start
button.
• When the machines beeps, note down
the displayed percentage value.
• This noted value is the Moisture
Content of the sample taken.
• MC for AB- 1.5, Tasty- 2, MD- 3
 Types of Leakage
1. Vertical leakage/ wrinkle- This type of leakage occurs in vertical layer
in the packet due to the sealing temperature of vertical cutter.

2.Micro Leakage- This type of leakage occurs in the horizontal layer of

packet due to the temperature variation of horizontal cutter. The
temperature of horizontal cutter is higher than vertical cutter.

3.JAW CUT- This type of leakage occurs a little bit cutting in the corner
of packet.

4.PIS- It stands for Product in Seal. This type of leakage occurs when
the timing of weigher of product dump and sealing of packet is
mismatch.

5.PIN HOLE- This type of leakage occurs when there is defect in roll
i.e., holes.

6.HSW- It stands for Horizontal Seal Wrinkle. This type of leakage

occurs when there is over lapping of papers due to unequal lay of belt.
 There 29 packaging machine in unit 2
10- Uflex for AALO BHUJIA
10- Uflex for TASTY
8- Uflex for MOONG DAL
1- New zipper
• About Uflex :
• Hopper–Product comes from weighing machine.
• Disc-It is used for measuring product weight.
• Shoot-It is used for laminate rolling.
• Vertical Filler- For vertical sealing.
• Horizontal cutter- For sealing and cutting of packet.
• Control Panel- monitoring the machine.
• Details Printed on The • Details on Carton Boxes:
Packet:

• Product Name
• Name of the Product & Company. • Weight of carton
• Nutritional Information
•
• Weight of 1 packet X No. of Packets
Ingredient’s list.
• Veg or Non-veg sign. • Total no. of Packets in carton
• Address of all 3 companies of Bikano. • Batch Number
• FSSAI Licence number. • Manufacturing Date
• Net weight of the product.
• Price of the product.
• Gross weight
• Manufacturing Date
• Batch Number
• Expiring Date
• Time and Machine the product was packed.
HACCP- Hazard Analysis Critical Control Point,
Critical Control Point (CCP)- any point or procedure in a food system where control can
be exercised and a hazard can be minimized or prevented.

GMPs- (Good manufacturing Practices)

i) Suitability of facilities
ii) Control of suppliers
iii) Safety and maintenance of equipment
iv) Cleaning and sanitation of equipment and facilities
v) Personal hygiene of employees
vi) Control of chemicals
vii) Control pests

6S followed in company-
i) Sort- separating useful and non-useful things.
ii) Set in order- keeping things at right place.
iii) Shine- cleanliness of area and machineries.
iv) Standardize- following set standard values
v) Sustain- following all the Ss.
vi) Safety- safety of us.
 CONCLUSION
Training at Bikanervala Foods Pvt. Ltd. as an intern has opened up my point of vision related to many
things such as managing of such a big company and taking measures to reach the daily goals. I
came across many difficult situations and learned from my mentors how to solve it. Some of the
things I have learned are as:

• How the production and packaging of foods products at such a large scale is managed.
• It’s too difficult to manage such a big organization, but proper team work and hard work pays off with
the completion of daily goals.
• Everyone in an industry are dependent on each other; hence proper coordination is mandatory to be
established within the organization.
• If a mistake have been made then how to solve it in a way that wouldn’t cause a huge loss.
• The efforts the Quality Department makes every day to maintain the quality production of the
products.
• In an organization higher post does not represent easy work life; but it comes with responsibility to
carry on the smooth functioning of the organization, which is very difficult task to maintain.
• With learning to calculate yield%, machine output, various lab experiments, and processes and
machinery involved in the production of food products; I had an experience which had made me
familiar with the working environment of an industry.
THANK YOU