Towards Partial Fulfillment of the Requirements for the

Degree of

Bachelor of Technology

In

Food Technology

SUMMER INTERNSHIP AT KANAK FOOD PRODUCTS

By

Hemya Singh

Under the Supervision of

Dr. Chanu Handa

AMITY INSTITUTE OF FOOD TECHNOLOGY

I-1BLOCK, IVth FLOOR, AMITY UNIVERSITY SECTOR-125, NOIDA, UTTAR

PRADESH
 ACKNOWLEDGEMENT

I am glad to present this report. Preparation of this report is based on coordination of so many
people that is very difficult for me to express my gratitude to them for their aid. However, I have
tried my best to acknowledge thanks.

I am highly obliged to my faculty guide Ms Chanu handa who gave me guidance and
motivation to complete the summer training. I am highly obliged to the acting head of Amity
institute of food technology Dr. V.K Modi and Dr. Naveen Sharma who provided me the
opportunity to undergo in plant training at kanak food products.

I am thankful to my industry guide Mr Naveen singh bisht who accepted me as an intern and
gave me the opportunity to work with kanak foods. I would like to thank Mr.Umesh yadav and
Mr. Narendra mehra who provided me with all the technical knowledge required.

At last I would like to show my thanks to entire staff and workers of kanak foods without whom
completion of this major project would have not been possible.

Hemya Singh

(A4312615026)

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 CONTENTS

Acknowledgment………………………………………..……………………………...…1
Table of content…………………………………………..………………………………ii
List of tables……………………………………………………………………………...iii
List of flowchart………………………………………………………………………….iv

Chapter 1 – Introduction…………………………………………………………………3
1.1 Company profile………………………………………………………….……….....3
1.2 Product profile……………………..………………..………………………….......3

Chapter 2 – Processing & Manufacturing..……………………………….………..9-28

2.1 Manufacturing process ………………………………………….........................9-12
2.2 Quality control………….. ………………………………………………….……..13-21
2.3 Testing…………………………………………………………..........................22-25
2.4 Utilities…………………………………………………………………..…………………26
Conclusion…………….………………………….………………………….........................27

References ………………………………………………………………………..…………..28

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 Chapter 1

INTRODUCTION

1.1 Company Profile

Started in The year 1995, Kanak Food Products gained hteir name under hte brand name
of Kanak and Himtop. Htey are one of hte major manufactures of pickle, squash, chutneys,
jams, ketchup and vinegar in uttarakhand. In uttarakhand Company has two plants, one is
present at Haldwani and one in Chakluwa Ramnagar which manufactures ketchup and
noodles.
This industry was started by Mr. Raghuwar Singh Mehra and has achieved various awards
for hteir products by uttarakhand government.
Kanak is a home where htere is mutual understanding between employee and employer
like members in hte family. It features a blend of hard work and dedication.
1.2 Squash

This is a type of beverage containing at least 25%fruit juice/pulp and 40-50% total soluble
solids, commercially it contains 1%acid and 600ppm sodium benzoate or 350 ppm sulphur
dioxide

It is diluted in a ratio 1:4 with water before serving

Fruits like pineapple, orange, mango, litchi, apricot, grapes are made commercially in indian
market.

1.3 Pickle

Hte preservation of food in common salt, vinegar and oil is known as pickle it is one of hte
most ancient methods of preserving vegetable and fruits. Htey stimulate hte flow of gastric
juice and thus help in digestion. Htey are considered as a good appetizers and add to hte
palatability of a meal.

In Indian market several kinds of pickle are sold. Mango pickle ranks 1 st in market followed by
lime, green chili, red chili, onion and cauliflower pickles.

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Pickling is a result of fermentation by lactic acid forming bacteria, which are generally present
in large numbers on hte surface of fresh vegetables. Htese bacteria grow in hte presence of 8-
10%salt solution and acidic medium, whereas hte growth of majority of undesirable organisms
is inhibited.

Lactic acid bacteria are most active at 30C, so this temperature is maintained during early
stage of pickling making. When vegetables are placed in brine, it penetrates into hte tissues of
hte former and soluble material present in htem and diffuses into hte brine by osmosis. Hte
soluble material includes minerals and fermentable sugars, sugar serves as a food to lactic
acid bacteria which convert htem into lactic acid. Hte acid brine thus formed acts upon
vegetables tissues to produce characteristic aroma and taste of pickle.

In a brine containing 10 % salt fermentation proceeds slowly. Fermentation take place to an

extent up to 15 % but stops at 20%stremghth.

Pickles are prepared with salt, vinegar, oil and combination of all three. In India we use
preservation with oil method for pickling. Vegetables are fully immersed in oil to restrict any
growth of microorganisms on it.

Chapter 2

PROCESSING AND MANUFACTURING

2.1 Squash Production

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 Fruits Washing Trimming

Juice
Grating Straining
extraction

Juice Preparation
Straining
measuring of syrup

Mixing with Addition of

Heating
juice preservative

Citric acid Stirring( brix

Bottling
addition 45 to 55)

Storage

Flowchart 1

2.1.1 Process for Juice Extraction

a. Selection of fruit –

 Fully ripe fruits are selected

 Over ripe and green fruits can adversely affect hte quality of hte juice

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b. Sorting and washing

 Damaged and decayed fruits are rejected or trimmed

 Dirt residues are removed by washing with water

c. Juice extraction

 Most of hte Juices are extracted with hte help of fruit pulper like litchi, apricot, apple,
pineapple, orange, bael and mausambi.
 Juice of grapes is extracted using basket press.
 Citrus fruit like lemon is cut into two halves and juice is extracted manually by pressing.
 Extraction work is done fastly and in enclosed room having air filters for avoiding hte
unnecessary exposure of juice to dirty air which can degrade colour, taste and aroma

d. Straining and filtration

 Extracted fruit juice contains various amount of suspended matter consisting of broken
fruit tissue, seed, skin, pectic substances and protein in colloidal suspension.
 Seed skin and pieces of pulp are removed using a thick cloth of size.
 Removal of all suspended matter is not preferred in case of squash as it results in
disappearance of fruity character and flavor of product.
 Hence a cloudy and pulpy appearance is maintained in hte juice.

e. Preservative

 Sodium benzoate and KMS (Potassium metabisulphite) are used as a preservative to

store juices in specified containers which can be used throughout hte year for
production of squash.

Pulp extraction method for various fruits

1. Bael 2. Guava

Ripe fruits Ripe fruits

 Breaking of Washing
shell

Removal of
pulp with Cutting into
seed and pieces
fibre

Mixing with Mixing with

water water (1:1)

Passing Passing
through through
pulper pulper

Pulp Pulp

Flowchart 2 Flowchart 3

3. Plum, Apricot and Litchi 4.Lime

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Ripe fruits
Fruits
 Washing
Washing

Addition of
water (1:0.5) Cutting into
halves

crushing Lime juice

squeezer

Heating upto
80c with
continuous Straining
crushing

Straining
Juice

Juice

Flowchart 5

Flowchart 4
Flow-sheet for Removal of Astringency from Orange Juice

Oranges

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 Diping Oranges
in Hot 2% NAOH
for 2-3 Minutes

Dipping in 0.5%
Citric Acid
Solution

For Juice
Extraction

Flowchart 6

2.1.2 Syrup Preparation

 Syrup is a mixture of sugar, water and acid which imparts extra sweetness and
tanginess in hte squash.

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  This also acts as preservative for squash and inhibits microorganisms to grow in squash
and increases its shelf life for years.
 Different fruits requires different syrup combinations like

Ratio of Water, Sugar and Acid required for various fruits

Orange, Mango and Pineapple 1:1.75:0.020

Litchi, Bael and Jamun 1:1.80:0.025

Plum and Apricot 1:1.90:0.010
Lime and Lemon 1:2

2.1.3 Action of preservatives

For making different type of fruit squashes two types of preservatives are used

1. KMS (Potassium Metabisulphite)

o It is solid and hence easier to use than liquid or gaseous sulphur dioxide
o It is stable in neutral or alkaline media
o It gets decomposed by weak acids like carbonic, citric, malic and tartaric acids.
o When it is added to squash it reacts with acid in juice forming hte potassium salt
and sulphur dioxide which gets liberated and forms sulphurous acid with hte
water of hte juice

CH2COOH CH2COOK

3K2O.2SO2 + 2C (OH)COOH 2C(OH)COOHK + 6SO2 + 3H2O

CH2COOH CH2COOK

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 Potassium metabisulphite + citric acid potassium citrate + sulphur dioxide
. + water
SO2 + H2O H2SO3
o Sulphur dioxide has a better preservative action than sodium benzoate against
bacteria and moulds.

Advantage of using sulphur dioxide

 Helps to retain color of beverage for longer period of time.

 Excess of sulphur dioxide present can be removed by heating hte juice to 71C or by
passing air through it.
 Being a gas it helps in preserving hte surface layer of juices.
 It Is Highly Soluble In Juices And Squashes, Hence ensures Better Mixing And
Preservation

Disadvantages of Using Sulphur Dioxide

 Cannot be used in case of some naturally coloured juices like plum, berry, grapes etc.
 Cannot be used for juices which are to be packed in tin containers, because it corrodes
hte tin causing pinholes. Also forms hydrogen sulphide which has a disagreeable smell
and reacts with iron of hte tin container to form a black compound.

2.1.4 Process Specifications

1. Sugar Storage Tank

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 Hte SCS line has one sugar storage tank. It has a maximum storage capacity of
2200litres. Hte sugar syrup stored in this tank is automatically pumped from hte sugar
syrup production li ne.

2. Mixing Tank

Htere are two mixing tanks in hte SCS line each having a storage capacity of 2500 Lt. a
buffer space is compulsorily left in hte tank over and above its total capacity to allow room
for error correction.

For example, if hte ready lot has a very high TSS or SO 2 content, hte buffer space allows
room for addition of ingredients thus allowing correction.

3. Washing of bottles

750ml bottles are washed manually in lukewarm water which is obtained from water
treatment plant.

4. Liquid Filling Machine

Hte Liquid Filling Machine has 6 nozzles and is auto set at 750 ml for filling of hte bottles.
Hte machine is directly connected to hte mixing tank via a pump to facilitate direct filling of
hte bottles. This unit functions with hte help of a sensor which identifies hte presence of a
bottle in hte bottle outlet. This sensing mechanism hterefore prevents hte wastage of hte
product during hte filling operation.

5. Capping-

This unit is equipped with a lid collecting unit which automatically slides down hte lids in a
position such that hte open side faces downwards. Like hte filling unit. Hte lid is attached
to each bottle by a simple rotation movement which fixes both hte lid and its seal to hte
bottle.

6. Washing chamber

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 Hte washing chamber is a very simple conveyer unit to which 22 sprayers are attached
throughout hte roof of hte chamber. Hte objective of this operation is to obtain hygienic
and clean bottles that can be distributed in hte market. Hte end of hte chamber has an
attached air-gun which facilitates hte drying of hte washed bottles. Hte objective of drying
is to facilitate easy and smooth sleeving.

7. Labelling

Sticker labels are applied to hte bottles and hte machine has a working capacity of 40
bottles per minute.

8. Coding

Each bottle is coded with hte month of manufacture, MRP and batch number. Hte coding
operation is achieved by an auto coding ink jet which prints hte code on each bottle.
Drying is necessary to prevent hte printed code from getting erased from hte bottle.

9. Packaging

Each packaged bottle is arranged in a carton which acts as a tertiary packaging unit. In hte
case of 750ml bottles, each carton contains 12units. Hte cartons are bought from anohter
facility and hte filled cartons are hten sealed and labeled with hte product name, batch
number and manufacturing month. Hte boxes are furhter sent for storage at hte
warehouse for furhter dispatch.

2.2 Pickle Production

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In factory pickle production was done manually in a pickling room which is divided into three
sections

Brine prep room, vegetable cutting and assembly. Below are some procedure for some pickles
prepaeration.

1. Mango Pickle

Mangoes Washing

Cutting(lengh Dipping
th wise 4 pieces in 2%
pieces) salt solution

Drying in
Adding hot oil
shade room
and spices
for few hour

Adding
Mixing hte
preservative
solution with
(sodium
pieces
benzoate)

Filling in Keeping it to
inside a process for 2
barrel weeks

Jar/pouch Addition of
filling extra oil

Storage Flowchart 7

2. Bitter Gourd Pickle

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Bitter gourd Washing
 Removal of
Making incision
pulp and seed

Mixing in salt Shade drying(2

(4%) hrs)

Mixing hot oil, Mixing hte

spices with lime solution with
juice bitter gourd

Adding
preservative
Barrel filling
(sodium
benzoate)

Keeping it to
process for Jar/pouch filling
weeks

Addition of
Storage
extra oil

Flowchart 8

3. Red Chilli Pickle

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Red chillies Washing
 Removal of
Drying
stem

Making Removal of
incision seeds

Mixing secret
Filling hte mix
spices,oil and
in chillies
seeds

Adding Filling it inside

preservative a barrel

Keeping it to
Jar/pouch
process for
filling
1.5 weeks

Addition of
Storage
extra oil

Flowchart 9

4. Green Chilies

Green chillies Washing 16

 Drying Making incision

Mixing spices in Mixing with

a lime juice chillies

Keeping it to
Filling it inside a
process for a
barrel
week

Addition of extra
Jar/pouch filling
oil

Storage

Flowchart 10

5. Cauliflower Pickle

Cauliflower Washing

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Cutting into 2- Shade drying
2.5 cm pieces for 2 hours
 Frying spices Mixing spices
with oil with pieces

Making paste
Adding to
of vinegar and
pieces
tamarind pulp

Adding Filling it inside

preservative a barrel

Keeping it to
Jar/pouch
process for
filling
1.5 weeks

Addition of
Storage
extra oil

Flowchart 11

6. Jackfruit Pickle

Jackfruit Washing

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Stepping in
Cutting into 10% salt
large pieces solution for
week
 Washing
Draining of
pieces with
brine
water

Frying vinegar,
Mixing with
jaggery and
pieces
spices

Adding Filling it inside

preservative a barrel

Keeping it to
Jar/pouch
process for 1.5
filling
weeks

Addition of
Storage
extra oil

Flowchart 12

2.2.2 Enumeration of Loss in Pickle Line

Dicer Loss

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  Dicing of mango, bitter gourd and jackfruit takes place in manually operated dicer. Hte
potatoes are fed from hte top of hte machine. Hte machine blades can be changed
according to usage big cuts, small cuts and long cuts.
 Formula used for calculation-

(Initial wt.-Final wt.)×100 = loss %

Initial wt.

Cutting Loss

 Ohter vegetables like cauliflower, lime and red and green chili are cut manually using
knives by some trained workers
 Formula used is same as above

2.3 Quality Control Department

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Hte Quality control laboratory in Kanak Foods is a well-equipped laboratory with an efficient
staff. Hte Quality Assurance Laboratory is a spacious facility planned with an aim to allow a
smooth flow of all quality checking procedures.

Analytical Procedures

1. Determination of Total Soluble solids by Refractometer

Refractometer Method (Determination of TSS by Refractometer)

 Mix hte sample well and make sure its temperature is between 25 0C to 270C.
 Clean and dry prism of refractometer using distilled water and soft tissue paper as cloth.
 Place hte sample on hte prism.
 Close hte prism carefully.
 Take hte reading by proper adjustment which is hte actual brix or TSS present in hte
sample.

2. Determination of Citric Acid content

 Weigh hte sample (not less than 10gm) in a conical flask.
 Add distilled water to dilute hte sample.
 Add 2-3 drops of phenolphthalein indicator.
 Titrate with 0.1N NaOH solution till pink end point is obtained.
 Note hte titre value.
 Calculate hte results as percent Citric Acid (Monohydrate)

Titre Reading x 0.70

% Total Acidity=
Weight of sample∈gms/ml

3. Estimation of Preservatives

a. Estimation of SO2 content

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 Sulphur dioxide (SO2) added to food products as a preservative may exist as
undissociated sulphurous acid, as free bisulphate ion, as free sulphite ion and/or
combined SO2 in hte form of hydroxyl sulphonates. Hte available methods for analysis
are eihter designed to measure hte total SO 2; hte combined SO2 is liberated by:
Treatment with excess alkali at room temperature, subsequent acidification to prevent
recombination and titration with iodine.
By distillation from acid solution and titration

Estimation by Ripper Titration

Principle:-

Ripper titration is a rapid analysis of hte SO 2 present in food products, added essentially in hte
form of NaMS or KMS as Class-II preservatives, permitted by hte PFA. Hte procedure
analyses hte amount of freely liberated sulphur dioxide. Hte treatment with 5N NaOH allows
hte dissociation and liberation of free SO 2. Acidification prevents hte recombination of hte SO 2
with its sodium or potassium salts. Furhter, hte sample is titrated against 0.01N Iodine solution
using starch indicator.

1ml of 0.01N I2 corresponds to 0.32mg of SO2.

Procedure:-

 Weigh 10gm/10ml of sample and dissolve in water.

 Add 5ml of 5N NaOH.
 Add 7ml of 5N HCl and shake well.
 Titrate rapidly against 0.01N Iodine solution using starch indicator to a dark blue end point.

1ml of 0.01N I2= 0.32mg SO2

Calculations:-

Titre reading X 10 X 32
ppm of SO2=
weight of hte sample

Hte maximum permissible limit of SO2 in squashes is 350ppm.

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 b. Benzoate analysis
Weigh 100gm/ml of sample in a 500ml volumetric flask. To it add saturated NaCl
solution. Add 15gm NaCl and make it alkaline to litmus paper. Dilute to mark with
saturated NaCl solution. Allow to stand overnight.

Procedure:-

 Pipette out convenient portion of filtrate into a 500ml separating funnel.

 Neutralize to litmus paper with dilute HCl (1:3) and add 5ml HCl in excess.
 Extract carefully with chloroform using successive portions of 70, 50, 40 and 30ml.
 To avoid hte formation of emulsion, shake continuously each time using a rotator motion.
(Chloroform layer usually separates on standing for a few minutes)
 Transfer hte combined chloroform extract from hte separating funnel to 250ml conical flask.
 Distill very slowly at low to ¼ of original and evaporate to dryness on water bath till only few
drops remain.
 Let hte residue dry overnight.
 Dissolve hte residue in 50ml alcohol and 15ml water. Titrate against 0.05N NaOH using
phenolphthalein indicator.

Calculations:-

Titrereading X Normality of NaOH X 144 X Volume made up X 1000000

ppmof sodium benzoate=
Volume taken for estimation X weight of hte sample X 1000

Hte maximum permissible limit of benzoic acid and its salts of potassium and sodium in
squashes is 600 ppm

4. Sugar Analysis by Lane and Eynon’s Method

Principle:-

Invert sugar reduces hte copper in Fehling’s solution to red, insoluble cuprous oxide. Hte sugar
content in a food sample is estimated by determining hte volume of unknown sugar sample/
solution required to completely reduce a measured volume of Fehling’s solution.

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A. Standard Glucose/ Dextrose solution
 Prepare 0.4% in water

Hence 0.4gm-------100ml

I.e. 4gm-----------1000ml

 Concentration of standard glucose/dextrose solution is 4mg/ml

Hence, 1ml-----4mg

a. Standardization of Fehling’s Solution:-

 Take 5ml of each Fehling’s solution A & B in a conical flask at 20-25ml of distilled water.
 Allow to boil and titrate with standard glucose till brick red precipitate is obtained.
 Add 2-3drops of methyl blue and continue till brick red precipitate reappears.
 Note hte end point. Repeat till you get consecutive reading. Hte titration should be
completed within 3minutes.

Fehling’s factor/mg of invert sugar= Titre reading X 4 = 14.5 X 4 = 58 mg of invert sugar

b. Sample Taken for Reducing Sugars

mg of invert sugar X dilution X 100 mg of invert sugar X dilution X 100

% Reducing Sugars=
Titre X weight of sample X 100 Titre X weight of sample X 1000

5. Salt %

Salt content is measured by titration 0.1 N of AgNO 3 with 10 ml sample prepared by taking 10
gm of sample whose volume is made up to 100 ml. Using 5% Cr 2O4 as indicator whose colour
changes from yellow to brick red. Hte amount of volume consumed of AgNO3 gives hte salt%

2.4 Utilities

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2.4.1 Boiler (Hte Heart of Every Industry)

All industries run on this basic unit that produces steam for carrying out all hte processes and
functions in an industries.

Hte boiler used in kanak foods is of hte “Smoke tube cum water tube”. Its capable of producing
5 ton steam from 5000 litre water, per hour. But hte daily consumption of hte industry is
approximately 10 ton per day.

Mechanism of Boiler:

Hte water used for boiler is Ro treated and hten softened by chemical. Hte charcoal
is lighted at hte base in hte fire place chamber and hte heat generated is blown over by air
from FD fan. This air carries hte heat upwards to hte water tubes, sotransmission its heat to
hte water. This water is reborn to hte steam, that's transferred to totally different lines as
per demand and in hte specific lines it’s used as per demand of specific product.

Hte waste material i.e. ash and hte gases emitted after combustion are removed out of hte
combustion chamber via, dust collector (i.e. ash collector) at hte basement and chimney for
gas emission.

2.4.2 Water softening

Hte water supplied to hte company is hard water. If this water is used to produce steam, hten
scaling may take place on hte inner surface of hte boiler, leading to decrease in hte efficiency
of steam production.
Thus water is treated with salt and hten passed through sand and raisin filter. Its capacity is 1
lakh. Hte water is first RO treated and hten softened and hten it’s checked for alkalinity, pH,
TDS and hardness.

CONCLUSION

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I got involved professionally & intellectually in various work activities during training period. Got
practical knowledge of various products right from raw material receiving to till hte finished
goods dispatch. Also got acquaint with hte various analytical tests which are carried out in a
Quality Assurance dept. Accepted hte challenges with open mind & positive viewpoint.
Adopted hte hard work, competency & consistency. Acquired hte knowledge, new skills &
techniques during training period
As we come to an end of our internship period, we learnt that hte quality of hte food product
must be maintained according to hte standards and it is one essential point which is to be
prioritized in hte overall food processing sector. Standard of national and international
industries for food concern should be important to maintain sanitation and hygiene in hte food
industries for food safety. Hterefore, hte food industries must have a speciality responsibility to
ensure that hteir products are safe as well as do well in hte market.

 Improved quality of product

 Achievement of greater consumer satisfaction
 Increase consumption and sales
 Promotion of national and international trade
 Greater confidence in hte mind of hte consumer.

Quality control is essential to food manufacturing and successful marketing of products of

national and international industries. As a result of quality control, following stages in
processing fields can be observed: -

 Minimal loss of raw material

 Full length inspection of finished products
 Sensory evaluation of hte products before final clearance
 Proper packaging procedures are followed
 Labelling and storage of hte finished product.

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 REFERENCES

 www.rip-publication.com.

 www.indiamart.com.

 www.foodtech.com.

 S Rangana Fruit And Vegetable Processing

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