BRITANNIA INDUSTRIES LIMITED

PERUNDURAI, ERODE

INDUSTRIAL INTERNSHIP ( MAY 2021 - AUGUST 2021 )

REPORT SUBMITTED BY,

ARUN K (2017016004)
KAMALESH V.S (2017016015)
VIJAYAKUMAR S (2017016046)

AGRICULTURAL ENGINEERING COLLEGE AND RESEARCH INSTITUTE

TAMILNADU AGRICULTURAL UNIVERSITY
COIMBATORE-641 003
2017-2021
 ACKNOWLEDGEMENT

We would like to express our gratitude to Prof. Dr. B. SRIDHAR, Dean, Agricultural Engineering
College & Research Institute, Tamil Nadu Agricultural University, Coimbatore for his kind help
in arranging our training at the “BRITANNIA INDUSTRIES LTD, PERUNDURAI”.
We also express our sincere thanks to Dr. M. BALAKRISHNAN Associate Professor, FPE, AEC &
RI Coimbatore & DR. P. SUDHA Assistant Professor, FPE, AEC&RI Coimbatore, Dr.PREETHA
Teaching Assistant, PHTC, AEC&RI Coimbatore.
Our grateful thanks to Dr. RAJKUMAR, Professor and Head, FPE, AEC & RI. For Granting
wonderful opportunity to accomplish our internship.
We wish to express our sense of obligation to Mr.Aravindh ( Human Resource Manager)
Providing us the opportunity for in plant training in their esteemed Britannia industry.
Our sincere thanks to Mr. Divakar (Production Manager), Mr. Mohanraj (Quality Manager),
Mr. Vengadesh, Mr. Vignesh (Quality officers), Mr. Nandha Kumar, Mr. Nagarajan (
Production Incharge) for Sparing time from their busy schedule and offering valuable
suggestions from time to time.
We are also thankful all Supervisors and Operators for extending the hands of co-operation.
This acknowledgement would be incomplete without thanking all the officers And all the
workers who have contributed directly and indirectly in successful completion of Our in-plant
training.

Date : 21/08/2021
Place : SIPCOT, PERUNDURAI, ERODE DISTRICT.

Yours sincerely,
Arun K (2017016004)
Kamalesh V S (2017016015)
Vijayakumar S (2017016046)
 CONTENTS

➢ INRODUCTION
➢ INTRODUCTION TO BISCUIT MAKING
➢ STORES
➢ MIXING
➢ SHEETING
➢ MOULDING/CUTTING
➢ BAKING PROCESS
➢ PACING
➢ STPCK AND FORWARING
➢ QUALITY WALL
➢ PERSONAL HYGIENE
➢ MEDICAL CENTRE
➢ MAINTENANCE DEPARTMENT
➢ ENGINEERING STORES
➢ PROJECT-PROBLEM STATEMENT
➢ OBSERVATIONS
➢ RESULTS
➢ PLANT LAYOUT
➢ CONCLUSION
COMPANY PROFILE:

Company Name Britannia Industries Limited

Headquarters Kolkata, West Bengal, India

Industry Food Processing

Parent Company Wadia Group

Founded 1892

CEO Varun Berry (Since 2014)

Revenue 11,878.95 crores INR (US$1.7 billion) – 2020

Areas served Worldwide

Website www.britannia.co.in
 INTRODUCTION

Britannia Industries is one of India’s leading food companies with a 100-year legacy and annual
revenues in excess of Rs. 9000 Cr. Britannia’s product portfolio includes Biscuits, Bread,
Cakes, Rusk, and Dairy products including Cheese, Beverages, Milk and Yoghurt.

Britannia is a brand which many generations of Indians have grown up with and is cherished
and loved in India and the world over. Brand Britannia is listed amongst the most trusted,
valuable and popular brands in various surveys conducted by prestigious organizations.

ABOUT THE COMPANY:

Britannia Industries Limited is a food company, which is engaged in the manufacture

of Biscuits, Bread, Cakes, Rusk, and Dairy products including Cheese, Beverages, Milk and
Yoghurt. The Company operates through the Foods segment, which
comprises bakery and dairy products.

The Company's product brands under the biscuits' category include Good Day, Crackers,
NutriChoice, Marie Gold, Tiger, Milk Bikis, Jim Jam + Treat, Bourbon, Little Hearts, Pure
Magic and Nice Time. Its products under breads include Whole Wheat Breads, White
Sandwich Breads and Bread Assortment. Its products under diary category include Cheese,
Fresh Dairy and Accompaniments. Its products under the cakes' category include Bar Cakes,
Veg Cakes, Chunk Cake, Nut & Raisin Romance, and Mufills. Its product under rusk category
includes Premium Bake.

The products of the Company are exported across the world, which include Gulf Cooperation
Council Countries (GCC), African Countries and American Countries. Its subsidiaries include
Manna Foods Private Limited and International Bakery Products Limited.

BRITANNIA - LOGO AND ITS MEANING:

Britannia's logo signifies, "rebranding as the Total Foods Company from now on with
the expansion of its offerings in both healthy and indulgent products. The wings of a bird
signify freedom to choose, whenever and wherever you want to enjoy your food."

BRITANNIA – MISSION:

The mission statement of Britannia says, "To improve the financial health of our
members and customers by satisfying their evolving borrowing, investment and housing
needs.
BRITANNIA - FOUNDER AND HISTORY:

• Britannia Industry was founded in 1892 by a group of British businessmen with an

investment of ₹295. Initially, biscuits were manufactured in a small house in central
Kolkata.
• 1918 - The Company was born on 21st March of the year 1918 as a public limited
company.
• 1921 - Britannia 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.
• 1924 - A new factory was established in the year 1924 in Mumbai. In the same year the
Company became a subsidiary of Peek Frean & Company Limited UK, a leading
biscuit manufacturing company and further strengthened its position by expanding the
factories at Calcutta and Mumbai.
• 1952 - The Kolkata factory was shifted from Dum Dum to spacious grounds at Taratola
Road in the suburbs of Kolkata. During the same year automatic plants were installed
in Calcutta.
• 1954 - The automatic plants were installed in Mumbai plant also in the same year the
development of high quality sliced and wrapped bread in India was initiated by the
company and was first manufactured at Delhi.
• 1965 - A new bread bakery was set up at Delhi in the year 1965.
• 1975 - Britannia Biscuit Company takes over biscuit distribution from Parry's during
the year 1975.
• 1976 - The company had introduced Britannia bread in Calcutta and Chennai.
• 1978 - The company made public issue, in that Indian shareholding crossed 60%.
• 1979 - The Company redefined itself from Britannia Biscuit Company Limited to
Britannia Industries Limited.
• Fast forward to Current Status, 2021 - Britannia is one of India's oldest existing
companies. It is now part of the Wadia Group headed by Nusli Wadia. Britannia's
revenue stood at 11,878.95 crores INR (US$1.7 billion) in 2020.
BRITANNIA – PRODUCTS:

Bakery Products : Biscuits account for 95% of Britannia's annual revenue. The
company's factories have an annual capacity of 433,000 tonnes. The brand names of Britannia's
biscuits include Vita Marie Gold, Tiger Biscuits, Nutri choice, Good day, 50-50, Treat, Pure
Magic, Milk Bikis, Bourbon, Nice Time and Little Hearts amongst others.

In 2006, Tiger, the mass market brand, realized $150.75 million in sales, including exports to
the U.S. and Australia. This amounts to 20% of Britannia revenues for that year.

Dairy Products : Dairy products contribute close to 5% to Britannia's revenue. The company
not only markets dairy products to the public but also trades dairy commodities business-to-
business. Its dairy portfolio grew to 47% in 2000-01 and by 30% in 2001-02.

BRITANNIA - BUSINESS MODEL:

The company operates in two business segments, namely, bakery products and dairy
products.The company derives ~95% of its revenue from the biscuits segment while,
5% of its total sales coming from non-biscuits category (dairy) and international market.

The company’s Dairy business contributes close to 5 per cent of revenue and Britannia dairy
products directly reach 100,000 outlets. Britannia Bread is the largest brand in the organized
bread market with an annual turnover of over 1 lac tons in volume and Rs.450 crores in value.
The business operates with 13 factories and 4 franchisees selling close to 1 mn loaves daily
across more than 100 cities and towns of India.

BRITANNIA - REVENUE AND GROWTH:

Between 1998 and 2001, the company's sales grew at a compound annual rate of 16%
against the market, and operating profits reached 18%. Presently, the company has been
growing at 27% a year, compared to the industry's growth rate of 20%. At present, 90% of
Britannia's annual revenue of Rs 22 billion comes from biscuits.

Britannia is one of India's 100 Most Trusted brands listed in The Brand Trust Report. Britannia
has an estimated market share of 38%.
BRITANNIA – ACQUISITIONS:

Britannia Industries, India's largest processed food company, has announced that it
has entered into an agreement with Fonterra Brands (Mauritius Holding) Ltd, Mauritius, for
acquiring the latter's 49 per cent Equity and Preference shareholding in Britannia New Zealand
Foods Pvt Ltd (BNZF), their Joint Venture Company engaged in Dairy business. This
acquisition is subject to Reserve Bank of India approval.

The company and its associates acquired majority stakes in Dubai-based Strategic Foods
International LLC and Oman-based Al Sallan Food Industries in March 2007.

BRITANNIA – COMPETITORS:

The top 10 competitors in Britannia Industry Limited's competitive set are:

• Parle Products

• ITC

• Horlicks

• Biskfarm

• Richfield Industries

• Frisco Foods

• Cookie Man

• MTR Foods Pvt. Ltd.

• Milo Australia & New Zealand

• Complan and Cadbury Bournvita

Its top Dairy competitors are:

• Nestlé India

• The National Dairy Development Board

• Amul
INTRODUCTION – BISCUITS:

The word biscuit derives from panis biscoctus which is Latin for twice-cooked bread
and refers to bread rusks that were made for mariners (ships biscuits) from as long ago as the
Middle Ages. The dough pieces were baked and then dried out in another, cooler, oven. They
were very unattractive being made more or less from flour and water.

The word ‘biscuit’ is an all-embracing term in Britain and several other countries. It
includes items also known as crackers (a term derived from the USA for thin, non-sweet,
products that made a noise of cracking when broken), hard sweet or semi-sweet biscuits,
cookies (which is a name that originated from the Dutch Koekje meaning a small cake) and
wafers which are baked between hot plates from a fluid batter. The name cookie was adopted
in North America where the term ‘biscuit’ can be confused with small soda-raised breads or
muffins. In other countries the term cookie is used principally for wire-cut products of rather
rough shape that often contain large pieces of various ingredients like nuts and chocolate. Thus,
the British tend to use the term biscuit for everything and the Americans do not use the word
biscuit for any of these items. Technically the difference between bread and biscuit is the level
of enrichment with fat and sugar, and the moisture content. Between cake and biscuit, the
difference is that of dough consistency, and again the moisture content. In general, biscuits can
be baked on a flat surface but cakes must be baked in containers because the dough is softer.

Although the first biscuits were dried-out rusks, useful as long-life food for sea
journeys, early cooks making confections with fat and sugar would have found that if little
dough pieces are baked in a typical hot oven and taken out when they have a good colour and
a stable structure, they would not have been dry enough to be entirely crisp. Putting them back
into a somewhat cooler oven to dry them out improved their eating qualities and also their shelf
life. Baking from the start in a cooler oven for a longer period allows drying but results in less
colouration and structure development. (The idea of separate moisture control from the
development of texture and colour is a technique that has been returned to relatively recently
with modern electronic technology as part of the baking process.) However, the term biscuits
were applied originally to dried bread pieces. These were also sweetened and flavoured with
spices. Other products like our modern biscuits were made but called by more cake-like names.
For example, shortcake and shortbread, short dough types are very ancient.
Biscuits are a very significant part of the food industry in most countries of the world. Their
success can be attributed to at least four key factors:

1. Their relatively long shelf life.

2. Their great convenience as food products.

3. The human liking and weakness for sugar and chocolate.

4. Their relatively good value for money.

 BISCUIT MAKING

CLASSIFICATION OF BISCUITS:

BISCUITS MAY BE CLASSIFIED IN VARIOUS WAYS AS FOLLOWS:

1. HARD DOUGH BISCUITS

In hard doughs the gluten is partially developed and to some extent extensible
depending on the percentage of sugar and fat in the composition. In this category the biscuits
that can be included are: Water biscuits, Sweet gluco biscuits, Semi sweet Marie type or cabin
biscuits and Some of the specialty biscuits having slightly higher percentage of shortening.Hard
sweet and semi-sweet: All these biscuits are characterized by doughs that contain a well-
developed gluten network but with increasing amounts of sugar and fat the gluten becomes less
elastic and more extensible. The prime requirement is a biscuit with a smooth surface, which
has a slight shine or sheen and an open even texture giving a bite that ranges from hard to
delicate. The majority of popular types now available, such as Osborne, Marie, Rich Tea and
Petit Beurre, all has very similar recipes and differ principally in their shape and thickness.

2. SOFT DOUGH BISCUITS

Short doughs, which are soft enough to be just pourable, are called as soft doughs.
Pieces are formed by extrusion in a similar way and in the same machine as wire cut and rout
biscuits but nozzles rather die holes are used to channel the dough. The dough is pressed out
either continuously or intermittently on the oven band that may be raised up and then dropped
if discrete deposits are requires. As the band drops, the dough pieces break away from the
nozzle. The biscuits produced in this way are usually rich in fat or based on egg whites whipped
to a stable form, the dough must be very short to allow it to break away easily as it is pulled
away from the nozzle. The nozzles through which the dough is extruded are usually indented
to give a pattern and relief to the deposits. Also by rotating the nozzles, swirls, circles and other
attractive shapes can be developed. In the case Spritz biscuits, the nozzles are oscillated from
side to side during continuous extrusion. This forms a ribbon of dough. Depositing allows not
very fancy shapes to be formed, but also by synchronizing two or more depositors, different
colored and flavored doughs can be combined. Jams and Jelly can be added on the top of dough
deposit. Fermented hard dough biscuits: In India fermented dough biscuits are prepared by
fermented slurry and then it is mixed with rest of the batch for dough mixing. Slurry is
fermented for 2-3 hrs only.
ROLE OF INGREDIENTS

Flour:

Flour constitutes the primary raw material to which all soft wheat product formulations
are related. It provides a matrix around which other ingredients in varying proportions are
mixed to form batter or dough systems. Most biscuits can be prepared from flour, which has
low quantity of protein and has a gluten content that is weak and extensible. Thus flour with
protein level of less than 9% is best and levels of more than 9.5% often create processing
problems. Flour should be shifted to aerate it for easy mixing operation.

Carbohydrates: The carbohydrates of flour are: Starch - 66 to 69%, sugars (glucose, maltose
and sucrose) - 1.4 to 1.6 %, other sugars - 0.9 to 1.2 %, hemicelluloses -2.3 to 2.5 %, cellulose
- 0.2 to 0.3 %.

Starch: Starch consists of microscopic granules or cells. Although starch is not soluble in
water, it absorbs moisture through its cells and hence the necessity of protecting flour from too
humid atmosphere. For complete gelatinization of starch, there should be sufficient (six times
of the weight of starch) water available and it should be heated to 140⁰ F. In case of bread,
water available to starch is insufficient and inner temperature of bread does not reach
gelatinization point until the last stages of baking and when the temperature does reach
gelatinization point the bread is taken out of the oven. Due to these reasons, starch in bread is
only partially gelatinized. When bread is hot, the starch cells are in swollen state. Position of
starch cells is unstable. This is the reason, why it is so difficult to slice very fresh bread. As the
bread is cooling down, starch cells shrink and become more rigid and slicing becomes easier.
During the cooling process starch cells give away some of its water, which is partially held by
gluten frame work and partially evaporated. When such bread is heated, starch cells again
absorb available water and become swollen. This is why stale bread becomes softer when
heated.

Sugar: Small quantity of sugar which is naturally found in flour is of sucrose or maltose type.
Even if sugar is not added to bread formula, it should be possible to make bread as the sugar
naturally occurring in flour will provide sufficient food to yeast to produce carbon di oxide gas.
However, apart from providing food for yeast, sugar has other function to perform viz.,
retaining moisture in bread, imparting golden brown colour to crust, improving taste and flavor
of bread etc. These beneficial effects cannot be achieved with the limited amount of sugar
naturally occurring in flour. Hence the necessity for using additional sugar in bread formula.
Protein: Maida contains soluble and insoluble proteins. Soluble proteins are useful in
providing nourishment to yeast for its growth and reproduction during fermentation process.
Two insoluble proteins “Gliadin and Glutenin” form a rubbery material when water is added
to flour and it is mixed. This rubbery material is known as “Gluten” and is responsible for
formation of structure of baked products. High structured products like bread will require
stronger quality of gluten while lower structured products like cakes, cookies do not require
strong gluten.

Glutenin gives strength to the dough in order to enable it to hold gases during baking
operation and, gliadin gives elastic or stretching properties to gluten. These qualities determine
the structure of the product.

Ash content: Ash content of flour is indicative of the degree of its purity with respect to bran
fragments. Higher ash content means that the flour contains too much of bran fragments. Apart
from darkening the colour of flour, the bran fragments also have a cutting action on gluten
fibres. Such flour will not retain gas during different stages of processing and the product thus
made will have a low volume and poor texture.

Moisture: The next important constituent of flour is moisture. A level of 13 to 14 % moisture

content in flour is ideal from bakers point of view. If moisture in flour is higher, the baker will
be getting less solid material and more of water for his money. Higher moisture will warm up
the flour during storage and will induce insect infestation, reducing its storage life. If the
moisture content of flour is high, it will reduce the Water Absorption Power (W.A.P.) of the
flour, resulting in less yield.
MAIDA FLOUR:

Maida is a finely-milled, white wheat flour commonly used in India. It is obtained

from the endosperm part of the wheat grain and can be made from winter- or summer-wheat
varieties. It is used in preparing breads and baked goods, noodles and other food products.
Current regulations in India require fortifying the flour with iron, zinc, vitamin A, folic acid
and other B-vitamins.

Function

Maida flour is low in protein (gluten), an advantage for producing high-volume, soft/tender
cakes with fine grain. Its high extensibility and stretchability are desirable qualities for a variety
of Indian pastries and baked goods.

Production

Modern Indian wheat flours are generally made using roller mills, known as ‘chakkis.’

Clean wheat is conditioned and cracked to separate the endosperm from the bran. Milling is
done in four or five stages resulting in different composition and particle sizes; subsequent
sorting produces whole meal (atta) and semolina-type (suji/sooji) flours and further milling and
sifting through 600 mesh and bleaching results in maida flour.

Within these types, there are finer divisions such as high gluten, medium and low gluten flours.

Nutrition

Maida flour is low in protein and fiber due to bran removal during milling.

Constituent Quantity (%)

Carbohydrates 72 to 75
Protein 11 to 12
Fat 1 to 1.2
Ash (Minerals) 0.4 to 0.5
Vitamins Traces
Moisture 12 to 14
There has been a controversy regarding bleaching maida flours with alloxan, a substance
banned by the Food Safety and Standards Authority of India (FSSAI). The chemical is a beta-
cell killer and can cause diabetes in humans.
SUGARS:

It imparts sweet taste, improves texture, crust colour and extends shelf-life. Selection
of the proper sweetener mostly is determined by the desired functions. The principal sweetener
used is sucrose (granulated sugar). Corn syrup, high fructose com syrup, invert sugar, honey,
glucose syrups and molasses are used to a lesser extent . Granulation of sugar is very important.
Coarse grain of sugar will cause more spread of biscuit affecting its texture, eating quality etc.
Very fine granulation will not incorporate enough aeration resulting in dense texture, toughness
and poor eating quality. Coarsely powdered or a fine granulated sugar should be used.

Functions:

➢ The principal function of the sugar is to provide sweetness to the product. However,
sugar less than 6% does not provide any sweetness.

➢ Sugar acts as a source of energy for yeast activity.

➢ Sugar being hygroscopic in nature, absorbs and retains the moisture hence the products
remain moistened for a longer time there by it improves the shelf life.

➢ Sugar caramelizes when heated, which provide dark brown color to the product.

➢ Texture, grain and crumb become smoother, softer and whiter with added sugar.
However, it may be due to action of sugar on delaying the gelatinization of starch and
the denaturation of proteins during baking.

➢ The flavor of the bread is also improved by sugar due to caramelization while baking
as well as due to production of various volatile acids and aldehydes during
fermentation.

➢ Sugar makes the product nutritious. Because it is carbohydrate, which provides energy
to the body after digestion.

➢ Improves the toasting quality i.e. similar to bread, improves the color and flavor of the
toast by caramelization.

➢ Addition of sugar increases the product yield.

In Britannia industries coarse powdered sugar were used,

➢ Coarse powder (i.e. fine crystal sugar) is used nearly for all purpose like creaming,
whisking etc. as it is free in grain and has no dust. Because when sugar creamed with
fat, the air cells are formed within fat-sugar cell wall. At this stage, if the granular
size is big, it will breakdown the cell. In both cases, the proper volume of the product
will not be obtained.

Invert sugar/syrup:

Invert sugar is a colorless, flavorless syrup which sweetens, improves quality and
extends shelf life of baked goods and confections. It is derived from sucrose (a.k.a. table sugar),
a disaccharide made of two monosaccharide sugar units.

When a disaccharide undergoes a process called inversion, it splits into its component
monosaccharides. In the case of sucrose, these are glucose and fructose. Fructose is much
sweeter than sucrose or glucose, making invert sugar is sweeter than sucrose.

uses

▪ Produces more rapid crust colouration.

▪ Imparts pleasing flavor.
▪ Imparts better spread, in the case of cookies.
▪ Extends shelf life in cakes and cookies by restricting crystallization of other sugar and
self - crystallization.
▪ It is used primarily for its hygroscopicity, in the products like cookies, cakes, icings and
pastes etc. that keeps products moist over longer periods. The quantity of invert sugar
used depends on types of product and the desired effects.

Sugar syrup:

These are widely used in yeast raised products and can also be used in chemically
leavened cake whose formulations call for a sufficient amount of liquid to accommodate the
water added with the liquid sugar.
Butter:

It is defined as the food product which is made exclusively from milk or cream, or both
with or without common salt and with or without additional colouring matter and contains not
less than 80% by weight of milk fat. Butter is used in baking industry primarily for its pleasing
flavor contribution, it imparts to the baked products. The flavor of butter is due to the presence
of butyric acid, lactic acid, di - acetyl, acetic acid, propionic acid and lactones.

Palm oil:

Palm oil has replaced all types of vegetable oils in bakery manufacturing . Palm oil is
imported from countries like Malaysia , Indonesia or Philippines . Cost is the biggest factor as
palm oil cost is cheaper than HVO ( Hydrogenated Vegetable Oil ) .Palm oil is also good for
health as conc. of saturated fat is low in respect to others. Palm oil is obtained from fleshy layer
of palm fruit without solvents or chemical . By treatment with steam followed by pressing .
The pressed oil is called crude palm oil . This palm oil is further refined using steam , vacuum
and clay to remove color and odour .

Palm oil following charateristics makes it favorite shortening.

✓ It has got natural anti oxidant s called tocotrienols which helps in protecting body
against ill effects of oxidation.
✓ It does not have transfat ie zero trans fat . Its composed of palmilic acid and oleic acid
✓ Palm oil is naturally semi solid at room temperature ( melting point is 39 deg c ) which
makes it an excellent shortening for food application . Palmilic acid imparts creamy
texture to the shortening which is important for baked products.

Palm oil naturally resists oxidation and hence provide longer shelf life to the baked products .
Shelf life and frying stability characteristics of palm oil are comparable to partially
hydrogenated vegetable oil.

Both forms of palm oil RBD ( Refined , bleached and Deodorised )-Palmolein and RPKO (
Refined Palm kernel oil ) are used in baked goods

LEAVENING AGENTS:

Leavening agents is defined that the substances, which help in increasing the volume of
the products, and make it more porous. Biological leavening agent and chemical leavening
agents are commonly used in bakery products.
 Yeast is unicellular organism belonging to fungi family. Now-a-days more than
500 yeast species are known. Out of that about 10 to 15 yeast species are used in baking
industry. Among them most important species for bread making is Saccharomyces cerevisiae,
hence it is known as bakers yeast. Yeast is produces by the fermentation of cane / beet molasses
It is responsible for fermentation and produces Carbon di oxide and alcohol, which provides
volume (makes bread lighter) and characteristic aroma and flavor respectively. Its structure
consists of a cell wall, protoplasm and vacuole. The average analysis of fresh yeast is: Proteins
- 14.0%, carbohydrates -10.2%, fats - 0.46%, mineral matter -2.34 %, moisture -73.0%,
enzymes - present and vitamins - present (vitamin B and C).

It requires food (in the form of simple sugar), moisture and temperate climate for
its growth and reproduction. Yeast multiplies by budding. When yeast cell is placed in a liquid
medium at optimum temperature( 80 ◦ - 85 ◦ F) containing simple sugar (dextrose or fructose),
then the cell starts growing buds on its cell wall which keeps on growing until the daughter
cells acquire the same size as the mother cell. Then the buds separate from mother cell and start
producing other buds.

The protoplasm of yeast contains certain enzymes by which fermentation activity of

yeast is made possible. There is no organism known other than yeast which contains the same
combination of enzymes in the same proportion. That is why there is no substitute for yeast as
a fermenting agent.

The following are most prominent enzymes which take part in fermentation process:

Invertase: Converts cane sugar or sucrose into a simple form of sugar known as invert sugar
which is a combination of dextrose and fructose.

Maltase: Converts maltose sugar into dextrose which is directly fermentable by yeast.

Zymase: Is actually the specific fermenting enzyme in yeast. Zymase attacks the invert sugar
and dextrose which had been previously produced by the action of invertase and maltase,
converting them into carbon di oxide gas, some pure alcohol, very small amount of glycerine,
succinic acid, acetic acid, lactic acid and other substances which make up for the peculiar,
pleasant fermentation flavor.
Protease: This enzyme has a mellowing action on flour proteins, thus conferring better
stretchability (on gluten) for bread to acquire volume and form structure.

The function of yeast is to raise and condition the dough so it turns from a heavy mass
into a light, porous, elastic product, which when baked, is appetizing, easily digestible and
nutritious. Without yeast, it is impossible to think of bread, buns etc as we know these products
today.

Chemical leavening agent

Various types of chemicals are used as leavener. The important leaveners are:

Ammonium carbonate or Bicarbonate (E 503 (ii)): It decomposes into ammonia, carbon

dioxide and water under heat and moisture. The advantage of this type of leavening agent is
that it decomposes in two gases and does not leave a solid residue, which makes problem in
case of sodium bicarbonate.

Ammonium bicarbonate is used in cookies, crackers and similar products where

the cellular structure is sufficiently porous to permit the slow escape of gases. If the gas does
not escape completely, the taste and odour of ammonia remains in the bakery product. That is
generally finds in high moisture products, thus limiting the use of this material to low moisture
cookie type products. In case of cookies, the ammonia portion increase cookie spread by
altering the protein structure, that is an additional function performs by ammonium
bicarbonate.

When ammonium carbonate or bicarbonate is heated CO2 and NH3 is produced. No solid is
left behind in this reaction. However, the ammonia imparts a detectable odour unless it is
completely removed. It is used in biscuits as they have large surface to mass ratio and ammonia
escapes when baked at high temperature. It can be used in products that are to be baked at low
moisture.

Sodium bicarbonate (E 500(ii)): Sodium bi carbonate is popularly known as baking soda,

which produces necessary gas for aeration either alone or mixed with a suitable acid. When
moistened and heated it gives off carbon di oxide but not the maximum of it unless it reacts
with a sufficient amount of a suitable acid.

When used alone as an aerating agent, the reaction that takes place is as follows:

Sodium bi carbonate Heat and moist Sodium carbonate + water + carbon di oxide.
Baking powders: Baking powder is the leavening agent produced by mixing an acid reacting
material and sodium bi carbonate with or without starch or flour as a filler. Since all baking
powders must consist of baking soda, the only way in which these can differ is in the type of
acid ingredient used. A baking powder should release its gas in the batter to saturate it with
carbon di oxide gas and then liberate the gas uniformly during baking to hold the raised batter
until it is set. This tends to give a uniform crumb and prevents shrinkage sakes from falling.
Baking powder is combination of sodium bicarbonate and an acid salt (phosphates, tartrates,
sulphates) when moistured and heating will evolve gas, which leaven the product giving it
volume and making light and easy to digest. Baking powder must yield not less than 12%
available carbon dioxide.

TYPES OF BAKING POWDER:

Fast acting baking powder: when this powder is used in a batter, a large portion of the carbon
di oxide gas is released within a relatively short time after mixing or while the batter is on the
bench operation and very little gas is released during baking. Example - tartrarte type powders.

Slow acting baking powder: Such baking powders do not release much of gas during bench
operation and all the gas is released when it comes in contact with heat (oven). Example - pyro
phosphate type powders, sodium aluminum phosphate type powders and sodium aluminum
sulphate type powders.

Double acting baking powders: Double acting baking powder contains atleast two acid
ingredients of both the fast acting and slow acting type. The fast acting ingredient is mono
calcium phosphate and the slow acting ingredient is usually sodium acid pyrophosphate or
sodium aluminum phosphate. In these products, a small portion of the carbon di oxide is
released during mixing at room temperature while on the bench operation and the remaining
is released in the oven beginning at about 40 to 43 ⁰C( 104 - 110 ⁰F).

Baking soda: It is chemically known as sodium bicarbonate. It will liberate CO2 gas, a
leavening gas, when heated. It also liberates the same gas when mixed with an acid, either hot
or cold. The popularity of sodium bicarbonate as a gas source is based on its low cost, lack of
toxicity, ease of handling very small contribution to the taste of the end product.
ROLE OF WATER:

Water is a component of virtually every ingredient, except a few like salt, sugar and
baking powder. It is also directly added into the preparations of most of the bakery products.
The chemical formula of water is H2O. It should be uniform in order to obtain products just
like any other common ingredients of bakery products. One can know from water supply
authority, whether the water supplied is constant in hardness and pH or its hardness and pH are
changed daily or season wise. If it is constant, baker may adjust the requirement of the water
according to formula, which probably will not encounter any problem in future. However, if
hardness and pH accordingly. For the same reason, a company having variety of water and then
rebuild it to a set figure artificially by adding required quantity of minerals. Simultaneously the
pH is also controlled by adding mild food acids or alkalis. This ensures that the quality of water
is uniform every day. This applies also to a single bakery whose water is subject to appreciable
changes.

Role/ Function

In baking, water plays an important role in production by providing (either by itself or

with other a substances) the necessary medium for the physical, chemical, biochemical and
biological reactions that underlie the transformation of raw material into finished baked foods.
In addition, it has a decisive influence on the overall quality and palatability of the finished
baked products. However the specific functions of water are listed below:

➢ The main function of water is to provide moistness to the product (i.e.act as a

moistening agent).

➢ Controls the consistency of the dough.

➢ Assists in the control of the dough temperature.

➢ Facilitates enzyme activity because enzymes can be activated in the presence of water
only.

➢ Makes possible gluten formation. Without water glutenin and gliadin present in the
flour cannot combine to form gluten.

➢ Wets and swells starch and renders it digestible.

➢ It dissolves salts, sugar, etc., suspends and distributes non-flour ingredients uniformly.
 ➢ Reconstitutes the milk or egg liquid from milk powder or egg powder.

➢ Keeps bread palatable longer if sufficient water is allowed to remain in the finished
loaves i.e. improves the keeping quality

➢ Water converts into vapour during baking, which requires more space and thus leavens
the products.

ROLE OF IMPROVERS

Quality of flour varies with consignment to consignment, a mineral content of

water varies from place to place and with complete mechanization of bread production process,
it has become unavoidable to make use of certain chemicals in order to ensure consistently
good quality of the product.

Gluten forming proteins of the flour is the basic factor for making good bread.
Strength and extensibility of gluten are the two main characteristics responsible for bread
making quality of flour. Flours always do not contain desirable quality of gluten forming
proteins. Any added material which can improve the strength and extensibility of flour is
known as Bread improver. Improvers can be divided into three categories i.e. Mineral
improvers, nutritional improvers and surfactant improvers.

1. Mineral improvers: Inorganic salts which affect the nature of gluten are known as Mineral
improvers. Mineral Yeast Food (MYF) is a general term used to describe a combination of
inorganic salts, some of which affect the nature of gluten while others act as food for yeast.
Potassium bromate, ammonium chloride, potassium iodate, calcium peroxide, calcium
bromated, calcium iodate, azidocarbonamide, lime water, phosphates, persulphates, sulphates
and organic acids.

2. Nutritional improvers: Improvers that increase the nutritional value along with the physical
qualities of product are known as nutritional improvers. It is also called enriching
improvers. Nutritional improvers include milk and milk products, malt and malt products, fat,
sugar, egg, potato and soy flour.

3. Surfactant improvers: Lecithins and GMS. They are surface active agents and also termed
as emulsifiers, crumb softeners, anti - staling agents or dough conditioners. They modify
the surface behaviours of liquids even though they are dispersed in low concentration. In yeast
raised products, addition of surfactants at appropriate level results in: increase in volume, more
tender crust and crumb, finer and more uniform cell structure within cell wall, brighter crumb
colour and slowing rate of crumb forming. In cake production, the effects of surfactants are:
more desirable grain and texture and better stability.

Lecithin: They were the first surfactants used extensively in the baking industry.
Commercially it is obtained chiefly from corn and soya bean oil. It is readily soluble in fats
and oils, hence, it is a general practice to mix it with fat before used in dough. It is used as per
the following rates: 0.15 to 0.25 %(on f.b) when product contains less than 8% shortening. 1
to 2% (on f.b) when product contains more than 8% shortening. In bread preparation lecithin
helps in : Increasing fermentation tolerance, producing better dough machinability, yielding a
more uniform crust colour, giving a more tender crust, providing smoother texture, providing
more uniform grain and giving softer and less rapidly staling quality of loaf.

However, if the amount of lecithin used is more than the recommended quantity it
may adversely affect the characteristics. In case of cake preparation, lecithin helps in giving:
better free flowing batter, more uniform colour, smoother texture, more uniform grain, better
keeping quality and greater flavor stability.

Glycerol Mono Sterate (GMS): It has a softening effect on the bread crumb and holds the
moisture for a longer period and thus acts as an antistaling agent. It is used in the form of
emulsion. Permissible limit is not more than 0.2% of dry GMS based on flour.

ROLE OF FLAVOURING AGENTS

It is an important ingredient in sweet goods. It is really ingredient, which helps the

baker to add uniqueness to the product. Appearance may be only an eye catching factor in the
first sale of any baked product but flavor holds the key to all the subsequent sales.

There are various sources through which baked products can acquire their flavor:

❖ The ingredient itself provides flavor to the product.

❖ Generally products develop their flavor during fermentation (production of acids,

alcohols) and baking (by caramelization) process.

❖ By addition of flavouring additives.

Types: It is divided into three categories:

a. Natural: Basic ingredients added in the formula like sugar and syrups, ground fresh fruit /
juice / pill (like orange, pineapple etc.), cardamom, nutmeg, cocoa, chocolate, etc. and the
essential oils of citrus fruits (such as lemon and orange) and vanilla extract.

b. Synthetic: It is the only practical means of flavouring in the baking industry.Natural flavors
are fortified with synthetic flavor will have more taste appeal than the natural flavours alone.

c. Imitation: Imitation flavours are not found in nature but are used to produce a natural flavor.
They are rarely used alone but are blended with fruit juices and essential oils to give better
results.

Skim milk powder

The dry products have the advantages over fluids products of reduced bulk, ease of
handling, no excess water to boil off in cooking candy batches, and long storage stability at
room temperature. When using dried skimmed milk powder it is advisable to add a small
quantity of lecithin with the fat to ensure complete emulsification of the milk in the batch.
Powdered milk is available as spray dried or roller dried product, the choice is governed by the
characteristics required. Spray dried powder has a considerably, larger surface area than roller
dried material, which affects the texture of fat based products. The flavour produced is affected
by the degree of caramelization produced during drying which is higher with roller drying than
with spray drying. Some milk powders are deliberately caramelized during processing. Milk
powders are difficult to reconstitute into solution or condensed milk compositions without
some grittiness being noticeable.

Sweetened condensed milk

This is available as the full cream product with 8% butter fat and added sugar, or as the
skimmed product with a much lower fat content. When using condensed milk it will be found
that the sweetened variety cooks with the smoother texture than the unsweetened and will of
course take less cooking owing to its lower water content. The unsweetened milk is liable to
curdle with prolonged cooking. Another point bearing in mind when using less sweetened
condensed milk is the fact that it does not keep well, once the can has been opened.
 The use of full cream condensed milk is currently uneconomical for products containing
4% or more of butter fat. Mixtures of skimmed condensed milk with sub sized butter or with
butter oil are cheaper.

Whey powder (or) lactose (or) Milk sugar

Spray dried whey contains 9-13% protein and 60-75% lactose. It is used in the
production of caramel colour as a seed material to induce formation of fine crystals in
condensed milk and in fudge made to contain high concentration of milk sugar. Delactosed
whey has excellent foaming properties. Lactose adsorbs pigments and odours readily and is
useful to fortify milk flavour in candy or especially chocolate. Condensed or powdered whey
has a considerable price advantage over the comparable condensed or powdered milks and can
be used to advantage in the cheaper ranges of caramels and toffees. Products made with whey
tend to be darker and have a noticeably different texture and taste. Ingredients based on whey
give lower viscosities than whole milk and softer textured confections which in the case of
toffees are subject to cold flow. It is advisable to use whey products as partial substitutes for
milk rather than as complete replacement. Blends of this type are available commercially and
do give toffees that reasonable those from whole milk. There is however, still a tendency to
cold flow, which makes them more suitable as chocolate centers than plain toffees.

DATEM (E472)

Diacetyl tartaric acid esters of mono- and diglycerides of fatty acids, or simply
DATEM, is an emulsifier used in bread and biscuits making to strengthen the dough structure
so that it can successfully expand during proofing and baking.

Function

It is used in bread, buns and many other yeast-leavened bakery products at levels of 0.2–0.6%
(based on flour weight). DATEM possesses excellent dough strengthening properties due to its
ability to adsorb at the gas/liquid interface of dough and stabilize the foam structure trapped by
the gluten matrix and prevent gas bubble coalescence.So, DATEM enhances gas (CO2)
retention and improves tolerance to shocks in case of mechanical abuse during final proofing
and baking. Due to its anionic nature, DATEM also has the capacity to interact with gluten
proteins, promoting protein aggregation.
SODIUM METABISULFITE (E 223)

Sodium metabisulfite is a reducing agent used in dough. It is used frequently in

cookie and cracker production.1 It is also used as a preservative for baked goods, wine, dried
fruit and jams due to its antioxidant capacity.

Function

As a reducing agent, sodium metabisulfite makes the dough flexible for better sheeting, and
this is the rationale for sodium metabisulfite’s working as reducing agent. It reacts with the
cysteine amino acids in dough, creating S-sulfocysteine residues within the protein structure,
which inhibit the restoration of disulfide bonds.

Essentially, sodium metabisulfite acts as a cap, covering the reactive thiol group on cysteine,
so it is unavailable to reform disulfide bonds. Lack of adequate disulfide bonds means that
dough can’t form a strong gluten network. Recent studies show that the presence of sodium
metabisulfite slows down the Maillard reaction, thereby reducing levels of acrylamide.

CALCIUM CARBONATE

Calcium carbonate (CaCO3) is an inorganic salt and food additive. It is used for a
variety of reasons in foods and bakery products. For example, it’s found as a:

• Dough conditioner
• Leavener
• Yeast nutrient
• Enhance nutritional value
Function

When added to bread dough, calcium carbonate can act as a dough conditioner and electrolytic
balance modifier for soft water. This is important for reducing dough softening or stickiness.
Other functions include:

✓ pH regulation and buffering effect

✓ Improving the nutritive value of baked goods
✓ Leavener by reacting with acids to produce CO2, especially in cakes
✓ Yeast nutrient in bread
✓ Activation of alpha-amylases
MANUFACTURING FLOWCHART:

PROCUREMENT AND QUALITY INSPECTION OF RAW MATERIALS

STORAGE OF RAW MATERIALS

MIXING INGREDIENTS AS PER STANDARD RECIPE

BISCUIT PIECE FORMATION

BAKING

COOLING

PACKAGING & LABELLING

STORAGE OF FINISHED PRODUCT

STORES

Store is the place where all the ingredients for biscuit making, raw material for packing
are received, stored and delivered to the respective departments.

In Britannia Industries Ltd., every department has its own specific function and are inter related
with each other. At the beginning of every annum, every department allocates a its own budget
and that is the target. Amount of materials to be purchased is targeted by the production
department and this in turn is indicated to the purchase department. Purchase department will
place the order for all the raw materials required by the production department.

All the raw materials are delivered to the stores directly by the concern suppliers. The supplier
should have the purchase order while delivering the materials to the stores The stores workman
will check the amount and type of materials received and direct them to the respective places
in stores. The stores officer will keep the accounts of the material received. After unlading and
storing of materials, the details of materials received is informed to the standards department
where quality of the material is checked. Standard department will decide the acceptance or
rejection of the materials received. As per the standards department result stores officer will
accept the material and mark as accepted and deliver the materials to the respective
departments. If the material is rejected and this is informed to the concerned supplier.

Duty of the stores is to take the account of incoming materials, delivery and stock everyday.
At the end of every month all these accounts are checked with the materials present in the
stores. In addition to this, stores will also keep the raw materials of ingredients used in biscuits
ie wheat is purchased, sold and then delivered to specific flour mill and from them, they get
maida. The by-products from flour mill are sold. For CB's also, the same procedure is followed.

Store officer should take note of expiry date for all the materials recebed and stond. If the
informed are nearing the expiry data, it is infimed to the production department or otherwise it
is sent to CP units. Based on the lead time, the materiel under is placed by the purchase
department.

All the waste gunnies, wrappers, barrels are sold by the stores Goods receipt records should be
maintained properly. Here FIFO is followed from this stores, materials are delivered to the
industries which are running as CP's for BIL . Based on modified value added duty (MOVAD),
the duty for the raw materials are made into account and this in turn is reduced finally in the
finished product duty. All the materials are stored in suitable temperature and place.
OPERATIONS CARRIED UNIT OUT IN MIXING

Several unit operations are carried out in mixing department for pre-preparation of
certain ingredients like SMBS, Lecithin etc.

Grinding of Sugar:

The sugar is fed into the feed hopper. Then pumped to the grinding unit. After grinding
delivered into the gunny bags. Sugar is used in powder form for all the biscuits.

Weighing:

All the ingredients are weighed and kept ready before mixing. Major ingredients such as maida,
fat, milk are added mechanically by programmed automatic systems.

Invert syrup preparation :

1)Weigh 165Kg of sugar & 48Kg of water. Also measure 2ml of Conc.HC1 & 500ml 50%
NaOH.

2) Add sugar and water in the stream kettle & stir till the temperature reaches 70-75°C

3) Add Conc. HCI slowly with stirring & keep for 45 min.

4) Add NaOH solution with constant stirring and keep for 10-15 min.

5) Transfer invert syrup to storage tank.

GMS paste preparation :

1) Weigh 50Kg of GMS powder 75Kg of HVO (NA) and 100Kg of Water.

2) Add GMS powder in steam kettle and heat to 60-65OC with constant stirring till it melts
completely.

3) Add HVO in the kettle & heat with continuous agitation till a homogenous mass is obtained.

4) Add water & SMBS powder in the stainless steel container & stir with mechanical stirrer
for 5 minutes.
Skimmed Milk Solution :

➢ Using deltamatic equipment with 10u mesh sievl, 300 litres of water is poured into milk
mixing tank
➢ Add 200 kg of powder.
➢ Mix 20-30 min.
➢ Confirming no clumps, liquid is pumped to chilling unit with filter at entry.

MACHINIERIES REQUIRED IN BISCUIT MANUFACTURING:

INGREDIENT HANDLING EQUIPMENTS:

• METERING:

Metering is probably the most important aspect of process control. Errors in metering
may have an effect throughout the rest of the manufacturing process. In most plants insufficient
is known about the precision of metering and deviations from standard are not recorded
systematically so comparison with biscuit size and quality is difficult or impossible. Various
metering systems with programmable logic controllers (PLCs) and electronic weighing allow
a much more scientific approach to mixing control and investigation of process difficulties. To
blame the flour quality for mixing faults, need no longer be the standard procedure. In most
factories, ingredients are metered to mixers by a combination of automatic (for bulk-handled
materials) and manual (for small ingredients) methods. In general, it is possible to programme
the order in which ingredients are put into the mixer and to preset the quantities required. Since
supplies for a number of mixers may be drawn from common tanks or silos, queuing or priority
programmes can be arranged and a mixing sequence will wait until a call for an ingredient has
been satisfied. Operator assistance can be called by means of alarms set to work should a wait
be excessively long or a preset weighing fall outside predetermined limits. Ideally, data on
weights or times for each mix should be logged to allow retrospective examination if necessary.
Pump-metered liquids are preset on a time or revolution basis determined by periodical
calibration. ‘Prompt’ signals may be shown to allow small and hand-metered ingredients to be
added and the operator acknowledges compliance by cancelling the call. Metering may also be
by a system of manual weighing, weighing-in, loss-in-weight or weighing the mixer. Each of
these terms will be described.
 • WEIGHING MACHINIERIES:

This automatic system results in pre-weighed quantities being dropped or fed to the
mixer as required. The weighing hopper or metering pumps may be immediately above the
mixer or remote. If the weigh hopper is immediately. over the mixer, it is dedicated to that
mixer and it must receive supplies from bulk silos which are probably shared by weighers
above other mixers. Whatever the means of sensing the weight, be it by a beam balance or load
cell, it will be necessary to have a valve system which closes the entry to the hopper when the
correct weight is made and any excess material in the conveyor from the silo must be diverted
back to the silo or to another container. The precision of the measurement is dependent on the
exact timing of the valve closure and this relies on a standard amount of ‘in-flight’ material
during the period between the signal to close and the completion of closure. As feeds from bulk
silos are always slightly irregular, the precision of weighing is adversely affected unless the
conveying rate is slow. However, it is normal to convey as fast as possible from silos so that
any weighers calling for material do not have to wait for long. Commonly, a weigher above a
mixer will be used to weigh both sugar and flour so having weighed the sugar this will be
dropped into a dump bin immediately under the weigher to be held ready while the flour is
weighed. When a call comes from the mixer either both materials or just that held in the dump
bin can be added at the desired time.
MIXING OF THE INGREDIENTS:

This is the crucial and beginning stage of biscuit making. Mixing Department is
responsible for addition of proper ingredients at correct level and time. This Department is also
in charge of giving desired dough to the manufacturing.

First, the mixing supervisors will select the maida for various biscuits based on standards result.
If there is any problem in manufacturing (like Shrinkage, Blowy Biscuits) the mixing time
adjusted accordingly. Mixers for developing hard doughs need to be very powerful and strongly
built. It is therefore not surprising that early biscuit dough mixers were slow and took a long
time to complete the mixings. Both horizontal and vertical style mixers with one or more
beaters were produced but the first ‘high-speed’ mixers were all of horizontal style. Supporting
(and sometimes driving) the beaters at both ends gives greater strength than the vertical mixers
where the beaters are in bearings only above the mixing bowl. Forming a good dough and
making many successive doughs of the same quality can be a critical operation. Many do not
know the definition of a good dough because they do not understand what is happening during
the mixing process. The aim of this chapter is to consider various aspects of mixing so that
parameters may be established for the mixing process based on optimising mechanisms for
particular types of dough. In the context of biscuit doughs, biscuit sandwich creams and batters,
the term ‘mixing’ covers a number of distinct operations. It includes

• The blending of ingredients to form a uniform mass

• The dispersion of a solid in a liquid, or liquid in a liquid

• The solution of a solid in a liquid

• The kneading of the mass to impart development of gluten from flour proteins which
have been hydrated at an earlier stage of the mixing.

• the build-up of temperature as a result of work imparted.

• aeration of a mass to give a lower density.

MIXER TYPES:

• BATCH MIXERS – Batch mixers are the most common type of mixers used in the
mixing process of the ingredients in industries. The beaters are mounted vertically and
either they and their drive mechanisms are lowered into a bowl or the bowl is raised to
locate with the beaters and a lid. The beater shafts may rotate on fixed positions, in
which case there are usually two or three beaters which intermesh with each other, or
there is a single shaft which rotates vertically and itself is driven in a circular, planetary,
manner. This action allows a single beater to reach all the dough in the bowl without
merely moving it in a circular motion. It is sometimes possible to fi t exchange beaters
of different shape and action and to drive them at different speeds. This allows a gentle
rolling and cutting action at one extreme to a vigorous whisking action at the other. The
larger mixers of this type can mix up to two mixes of hard doughs and around three
short doughs per hour. Most large batch mixers traditionally have two-speed motors
(‘low’ and ‘high’ speeds) but the two-speed motor is gradually being superseded by
variable frequency drives. This gives more process flexibility in that the blade speed
can be adjusted. What the ideal speed programmes are need to be established
experimentally. The capacities may be based on ‘sacks’ of flour (about 125 kg) but this
is not very helpful where large amounts of sugar, fat and other ingredients are included
in the recipes. Alternatively, capacities may be based on volume such as 100, 200 or
500 litres (be clear whether the volume is an absolute value or the useful volume where
the beaters sweep the dough). As a rough guide, volumes of 100, 200 and 500 litres
relate to recipes containing 32, 64 and 192 kg of flour, that is about 60, 120 and 360 kg
of dough.

• CONTINUOUS MIXERS - These are generally of a rotor-within-a-barrel variety. By

arranging different arms and stators along the length, it is possible to alter the mixing
actions within the range of blending, dispersing, aerating and kneading. Multi-section
water jackets allow excellent temperature control and by adjusting the barrel length
dough retention and mixing times can be suited. Also, the overall capacity of the mixer
is usually flexible. It is possible to feed all the ingredients at the start of the mixer or
have successive ports along the barrel so that different additions can be made after
appropriate intervals.
Mixing is done in two stages. Creaming stage and mixing stage.

Creaming Stage:

All the ingredients except the flour and acetic ingredients are mixed first at gentle speed.
Mixing time depending on the type of mixer ranges from 10-15 minutes. The object are to
dissolve as much sugar as possible in the available water and disperse milk solids, chemicals,
flavours and emulsifiers etc. This results in semi-stiff white cream.

Mixing Stage:

The flour is then added to the cream and mixing proceeds until uniform depression of cream
over the flour takes place. The result is crumbly dough which can moulded via rotary moulder.

Mixer:

Here horizontal type mixer is used. Mixing bowl is not detachable and mixing arm is in
horizontal position. This could be sub-divided into "Z" blade and high speed. The "Z" blades
are set in U shaped bowl. The arms are so designed that they rotate at different speeds and force
the mixer from one arm to other, stretching. shearing and forcing the ingredients form the
dough.
SHEETING OF DOUGH:

After mixing, dough may be rested, allowed to ferment, cured, or it may be taken
immediately to the hopper of a sheeter. The function of the sheeter is to compact and gauge the
mass of dough into a sheet of even thickness and at full width of the plant. It is necessary that
there are no significant holes in the dough sheet and that the edges are smooth and not ragged.
Often the sheeter also enables the incorporation of dough returned from the cutter, known as
cutter scrap, with fresh, or virgin, dough brought from the mixer. Within the sheeter the dough
is compressed and worked to remove air and it is inevitable that some stresses are built up in
the gluten structure. There is also a small increase in dough bulk density. Flanges at the ends
of the rolls prevent the dough being extruded from the ends of the rolls and ensure that the
emerging sheet is always of the desired width. The new sheet of dough then passes to one or
more sets of gauge roll pairs which reduce the thickness to that required for cutting. Like the
sheeter, there are flanges on one of the gauging rolls to prevent the dough extruding sideways
and to maintain a full width of dough sheet.

Sheeters are available with either two, three, or rarely four rolls. The two-roll varieties
are usually used as pre-sheeters. that is, they meter the dough from a hopper as a rough or
incomplete sheet to other machinery such as a rotary moulder or a threeroll sheeter at the head
of the cutting machine. The performance of pre-sheeters is usually not critical as they are not
designed to produce a perfect sheet of dough.

The configuration of the rolls is designed to compress and gauge the dough into an
even full-width sheet. The two top rolls are known as forcing rolls and then one side of these
rolls plus the lower third roll constitutes the gauging facility for the emerging sheet. In order to
draw the dough into the sheeter, at least one of the forcing rolls has a rough surface in the form
of fluting or grooving. To ensure an even pulling of the dough into the sheeter it would be best
if both rolls had similar roughened surfaces, but the problem is that if both forcing rolls have
grooved surfaces a pattern will be given to one surface of the emerging dough sheet. Two-roll
sheeters do not have the forcing or compression facility and consequently are apt to give sheets
which are holey or have ragged edges. For both threeand more particularly two-roll sheeters,
the shape of the hopper is more important than is generally recognised.
The laminator reduces the dough to a thin sheet in successive stages and thus compacts into a
laminated structure. Occluded air is eliminated from the dough and the strains produced by the
rollers are equalised.

Lamination is important due:

• To built flaky structure in biscuits.

• To give uniform surface of the dough.

• To control the shape of the biscuits.

• To eliminate occluded air.

CUTTING:

Most biscuit plants always employed reciprocating cutting machines. These used heavy
block cutters which stamped out one or more rows of pieces at a time. The equipment needed
to be strong and incorporated a swinging mechanism so that the dough sheet travelled at
constant speed and the cutter dropped, moved with the dough, then rose and swung back before
dropping again. There were two basic procedures used depending on whether merely cutting
or embossing and cutting was required. Where simple cutting and dockering was needed, as
for most crackers and hard sweet types, the cutting edges, docker pins and any type of
decorative patterns were mounted on a baseplate and a spring-loaded ejector plate was located
to move vertically around the fixed parts. When the cutter dropped onto the dough the ejector
plate was pushed back and as the cutter was lifted away the ejector pushed the dough to ensure
it stayed on the cutting web and did not stick to the cutter. If there was a tendency for the dough
to stick to the ejector it was necessary either to lightly dust the dough sheet with flour, or to
affect a little drying with a blast of air before the cutter.
ROTARY MOULDING FOR BISCUITS:

Most biscuit rotary moulders involve the extraction of dough from filled moulds. w. It
is, however, necessary to mention that there are other, smaller unit moulding machines where
the formation of the dough piece is different. In this dough is forced between two rolls one of
which is the moulding roll (often ceramic) and has cups formed in its surface. As the dough
leaves the nip of these rolls it sticks to the forcing roll as a thick blanket. On the surface of this
blanket are the raised embosses of the dough extracted from the cups in the moulding roll.
These areas of dough are cut from the underlying blanket with a vibrating knife and transferred
onto a conveyor to take them to a baking tray or the oven band. The form of the machine is
thus very different in design from the main mass of biscuit rotary moulders. These machines
are not suitable for high-speed work nor are they made in the widths common for biscuit plants.
By adjusting the position of the knife, it is possible to control the dough piece weights but there
is often a problem in transferring the doughs without distortion across the knife and onto the
takeaway conveyor. This type of moulder is best for small-scale production where the dough
pieces are baked on trays.

Relaxing Web:

As the dough passed through different rollers and compressions, it results in added stress to the
dough. If the dough sheet is subjected to cutting at this stage, it before cutting. In this, the dough
coming out of the final gauge roll forms ripples due results in deformation of the biscuits.
Hence, the dough sheet need to be relaxed to different speeds and finally fades away when it
enters the cutter web.
Scrap removal:

The remaining portions after cutting is called as scrap and need to be processed by
incorporating the same into the fresh dough. Preferably, dough sheet coming out of the scrap
dough need to be placed below the fresh sheet so as to get good shine.

BAKING PROCESS:

The baking and drying of dough is the essence of biscuit making. The first biscuits were
dried out slices of bread (rusks), useful as long-life food for sea journeys. Later plain, more or
less flour and water, doughs were formed into flat pieces for baking and drying and were known
as ships biscuits. The drying of these was of very great importance to give long life. Early
cooks making confections with flour, fat and sugar would have found that if little dough pieces
are baked in a typical hot oven and taken out when they have a good colour and a stable
structure, they would not have been dry enough in the centres to be entirely crisp after they
cooled. Putting these baked pieces back into a somewhat cooler oven to dry them out improved
their eating qualities and also their shelf life. This is probably the origin of the name ‘biscuit’
meaning twice baked. Baking from the start in a cooler oven for a longer period allows drying
but results in less good colouration and structure development. Baking times for biscuits are
quite short, ranging from 2.5 to 15 minutes with a mean at about 6 minutes, and as it is not
normally possible to change the temperature in a static oven quickly, the results of baking in
these ovens compared with that in travelling ovens are often very different. Experimentation
to determine optimum conditions for baking in a travelling oven requires a constant supply of
uniform dough pieces so is potentially a time-consuming and expensive business. This has
resulted in a situation where the facility to change the oven conditions through the bake is not
always used to maximum advantage for a particular type of biscuit.

Baking is another important stage of production which is just as mixing. forming etc. changes
during baking is associated with:

• Development of Rigid porous structures.

• Reduction in moisture.

• Surface colouration.
Changes involved during baking are

a. Gelatinisation of starch

b. Liberation of gases

c. Expansion of gases

d. Rupture and Coalescing of some of these bubbles

e. Loss of water vapour.

The starch gelatinisation occurs at 55-65°C and proteins are denatured at 70°C. Gases liberated
at 65°C. Fat melting is at 50°C.

OVEN TYPES:

Most biscuits are now baked in travelling ovens but many small manufacturers bake on
trays placed in a static oven which may be one of the following types:

• Peel or sole plate, where the trays are placed on the floor of the oven

• Reel, where the trays are placed on platforms that rotate in a horizontal plane when the
oven is closed

• Rack, where trays are placed in racks that are then wheeled into the oven and rotate in
a vertical plane when the oven is closed.
COOLING OF BAKED BISCUITS:

After baking the biscuit must be packaged or passed for secondary processing such as
chocolate coating. Packaging involves not only grouping into practical sizes for sale, but also
protection from moisture uptake from the atmosphere, dirt and damage. It has been usual to
cool the biscuits before packaging. A drop of temperature of the baked biscuits is necessary if
the biscuits are to be manually handled, sandwiched with cream or chocolate coated, etc. In
addition, some other changes may occur. There may be a small loss in moisture, though this is
normally insignificant, but moisture gradients within the product will be partially relieved and
the structure will become more rigid (especially in sugar rich products). In most factories,
biscuits are not packed hot and it is therefore important to consider the conditions for cooling,
the cooling requirements and the consequences of not cooling and handling biscuits correctly
before packaging. In the early days of biscuit manufacture, biscuits were left to cool on the
trays upon which they had been baked. With travelling ovens, the biscuits are stripped from
the baking band and passed onto conveyors that take them to a place for packaging or secondary
processing. These conveyors provide the opportunity for the biscuits to cool. Little critical
investigation seems to have been carried out on the ideal/minimum time required for cooling.
If the exposure to the air is too long the cost and maintenance of the long conveyors is a waste
and it may be that, under conditions of high atmospheric humidity, some moisture is picked up
by the biscuits before they are packaged. If the cooling is too little, hot biscuits may cause
shrinkage and distortion of wrapping films, melt cream in a sandwich or cause loss of temper
in coated chocolate.

Then biscuits are manually transferred to wrapping machines, etc., after cooling it is
clearly necessary to have the products cool enough for handling. With the introduction of
mechanised handling, it is not necessary to worry about what is acceptable to human hands but
many feels that if the biscuits are packed too hot, they will sweat in the pack. In other words,
there is thought to be a significant loss of moisture while the biscuits are cooling. It is probable
that cooling arrangements are mostly excessive. The ‘rule of thumb’ cooling times on open
conveyors given by machinery suppliers range from 50 to 200% of the baking time. In some
cases, biscuits are stacked immediately after removal from the oven band and then cooled on
wire conveyors with fans blowing air from below or in forced convection tunnels with or
without refrigeration. Long cooling conveyors usually involve transfers and often turnovers
between the oven exit and the final destination. With increased mechanisation of biscuits, it is
most important that the uniform orientation of the biscuits on the oven band is maintained to
the handling machines before wrapping, etc. A jumbled positioning means that the handling
mechanisms are less efficient. The longer the cooling conveyors and the more the transfer
points, the more disorientated becomes the biscuit positioning. There is thus a need for minimal
cooling and transportation before packaging. Because the optimum conditions for biscuit
cooling seem so vague the author undertook to make some measurements which should form
a better basis for determining cooling requirements. The temperature of various types of
biscuits was measured at intervals after leaving the oven band and also at the stacker
immediately before packaging. He also checked the weight loss during the cooling period to
determine the moisture losses. His findings and conclusions are as follows.

Long cooling conveyors usually involve transfers and often turnovers between the oven
exit and the final destination. With increased mechanisation of biscuits, it is most important
that the uniform orientation of the biscuits on the oven band is maintained to the handling
machines before wrapping, etc. A jumbled positioning means that the handling mechanisms
are less efficient. The longer the cooling conveyors and the more the transfer points, the more
disorientated becomes the biscuit positioning. There is thus a need for minimal cooling and
transportation before packaging.
PACKAGING OF BISCUITS:

The last part of the biscuit-making operation is the packaging. Biscuits leaving the oven
or secondary processing should be of correct shape and appearance and, when cooled, in prime
condition for eating. The object of packaging is to collate the biscuits in groups of suitable size
for sale and to protect them so that their flavour and appearance is preserved for as long as
possible. The majority of biscuits are sold in 200 g packs, but packs range in weight from only
a few grams, if a single biscuit, to 300 or 500 g in ‘family’ packs. Sometimes much larger units,
particularly in tins, are packed and there is also a growing demand for very small packs of only
a few biscuits suitable for vending machines or individual snacks. Attention to detail in terms
of labour utilisation, presentation of the biscuits to both the packaging operators and the
wrapping machine and the handling of wrapping materials and packed stock, will have
important effects on the efficiency and costs of production. The packing area has received much
attention for mechanisation to reduce labour. This has been through automatic feeds to
wrapping machines and the use of robotics to pick and place biscuits precisely into positions
for final wrapping. Customers demand a variety of biscuit shapes and types in packs of different
sizes.

The primary pack is the moisture-proof unit which is to be offered for sale to the consumer.
Secondary packaging into groups of 10, 20 or more in boxes or cases is for ease of storage and
transportation, but as this packaging may have a significant effect on the mechanical protection
afforded to the primary packs, it should be designed carefully. Primary packages are of only a
few basic types. The wrapper may be rigid in the form of a tin or plastic box, but much more
commonly it is some form of flexible material. If flexible it may be a pre-formed bag which is
sealed after the biscuits have been placed in it, or it may be formed around a group of biscuits
and heat sealed automatically. Some biscuits are collated and placed into pre-formed bags
which are hand sealed, but by far the most common form of biscuit packaging is with
sophisticated machines which carry groups of biscuits through wrapper forming.
STOCK AND FORWARDING

There are many systems for store mechanisation and computer control which allow
automatic placement and retrieval of palletised stocks. Management is thus provided with
constant information of stock levels and correct rotation of stock is assured. The cost of such
systems may be offset by the reduction of labour required and facilities to use high buildings
with purpose-built racking. High buildings require close attention to air circulation to avoid big
temperature fluctuations near the roof.

Once the biscuits have left the factory site, they tend to be forgotten in terms of quality
control, yet care is necessary right up to the point of sale in shops. Conditions of temperature
and humidity are very important in biscuit stores. High or fluctuating temperatures may cause
fat migration, fat bloom, chocolate and rancidity problems. High humidity or dampness will
reduce the strength of the cardboard cases and increase the rate of moisture transmission
through wrapping films. Thus, all parts of biscuit stores should be dry and cool. Good insulation
of walls and ceilings combined, if necessary, with air conditioning and air circulation will
reduce the chance of local high or fluctuating temperatures. Stock and Forwarding is the final
place from where the biscuits are ready to enter into the market. From the packing sections, the
packed corrugated board boxes (CBBS) enters into S & F through conveyors. From the
conveyors, the CBBS are taken and arranged in S & F. Here FIFO (First in First Out) system
is followed i.e. whatever product with code is carried in first should be carried out first. All the
accounts for all the products, entering into the S&F is maintained properly by the S & F
officers. Once if the product reached the S & F, it should be taken out only after paying the
duty. Checking or opening of CBBs is also not permitted. The duty for the final product is
reduced by crediting the duty paid for the raw materials in the general stores. From the S & F,
the products are carried out to C & F (Carrying and Forwarding) from where the products are
delivered to the whole sellers. The company itself has C & F in all the areas.
CONTROL POINT IN BISCUIT MANUFACTURING:

• WEIGHING ON INGREDIENTS - Lack of use of standard weights and scales causes

a lot of problems in bakeries. As bakeries use a lot of ingredients and additives essential
for the process example baking soda, artificial colour and flavour. If ingredients are not
in permissible limits, the products will be termed as adulterated or misbranded.
Formulating standard recipes and training the staff the importance of correct usage of
weights and scales is important.

• MIXING - Mixing step where all the ingredients are mixed to form a dough. Often
special mixers like spiral or rotator mixers are used for this purpose. Care should be
taken that these are always maintained in the best of condition. Any loose parts should
be repaired immediately to avoid physical contamination. Blades of stainless steel
should be preferred over plastic ones. Often this might be semi-automated activity, so
the personal hygiene of the person handling the mixing should be tended to as
contamination can occur at this point.

• KNEADING - Kneading is often a step facilitating better gluten formation resulting in

a soft fermented product. Care of the personal hygiene should be taken if the process is
manual and loose parts or blades should be checked if it’s an automated process.

• PANNING/ MOULDING - This step consists of addition of dough into moulds or

pans for further baking step. These should be preferably made with stainless steel of
food grade material and use of plastic should be avoided.

• BAKING - The time and temperature relationship is very important for the product to
bake as well as eliminate the microbes. This relation needs to be studied carefully. It is
a CCP in the bakery process. Use of temperature display, recording devices are
necessary and helpful for ovens. Yeast dissipation of the oven is important, insulated in
case of wood fired oven or diesel fired so that smoke can be let out directly and the
temperature in the manufacturing premises does not rise.
• COOLING - Proper cooling is essential after baking. The product should come to room
temperature naturally before packaging. Improper cooling will lead to condensation in
product after packaging and early spoilage due to microbial growth. Cooling should
also be done in clean and cool air so as to avoid contamination of product.

• PACKAGING/ WRAPPING - Packaging is done as a medium to safeguard the food

from external spoilage as well as means to provide product information to the
consumer. Most of the small bakery units refer doing manual packaging rather than
installing automated packaging. Or it is a semi-automated activity example; biscuits are
first manually packed in trays and then sent on conveyors for packaging. Often a metal
detector step should ideally be incorporated during packaging to rule out possible metal
contamination. This metal detection is considered as CCP so that metal contamination
if caused while processing and packaging can be controlled.

• PRODUCT STORAGE - Product Storage is temperature sensitive, can be classified

into: Ambient storage for dry products like Khari, toast , bread, biscuit. Chocolate and
fresh cream cakes, pies, pastries. Product storage should be away and separate from
Raw material storage to avoid cross contamination. Product should be stored on pallets
and away from the wall and not the floor, near the wall. - Product stacking should be
appropriate so that the lower boxes or wholesale packages maintain their integrity and
do not get crushed under pressure. Product storage should be labelled and classified
according to the product for easy product flow and dispatch. Products should be stored
facilitating First- Expiring- First- Out (FEFO) to maintain stock rotation. Use of
temperature and humidity recording devices are helpful to maintain the FSMS. Product
recalled or withdrawn from the market should have segregated storage.
 CLASSIFICATIONS OF BISCUITS:
TYPE DESCRIPTION EXAMPLE

Hard Dough Low Fat, Medium Sugar Marie gold

Short dough High Fat, High Sugar Milk Bikis, Good day
Fermented dough Low Fat, Low Sugar 50-50

50 50
MANUFACTURING PROCESS OF 50-50:
INGREDIENTS USED:
1. SLURRY:
Refined Wheat Flour, Water, Powdered Sugar, Yeast Solution, Pancea,
Fungamyl, Neutrus, Papain, Acidic Calcium Phosphate, Citric Acid.

2. SPONGE:
Refined Wheat Flour, Invert Syrup, Yeast, Powdered Sugar, Ammonium
Bicarbonate, Palm Oil and Water.

3. DOUGH:
Slurry (1 Batch), Sponge (36.3 Kg), Refined Wheat Flour, Refined Palm Oil,
Sugar, Water, Invert Syrup, DATEM, Iodized Salt, Lactic Acid, Flavors, Montreal Sugar,
Sodium Meta Bisulphite, Sodium Bicarbonate, Ammonium Bicarbonate and Processed Dust.

PROCESS STEPS:
1. DOUGH PREPARATION:

a) SLURRY PREPARATION:
The slurry is prepared in a single mixing process in a horizontal batch
mixer. All the ingredients were loaded into the mixer at the specified amounts and the mixing
is done for about 4 minutes. Then, the dough is unloaded in trolleys and left to stand for about
45 minutes for the yeast action. After 45 minutes of standing, entire single batch of slurry is
used in the preparation of single batch of the final dough. Slurry is prepared continuously
during the entire shift of 8 hours.

b) SPONGE PREPARATION:
The sponge preparation involves the two-mixing process, which is
before and after addition of refined wheat flour. Initially, all the other ingredients other than
refined wheat flour is mixed in the first process, this is called as creaming step and it lasts for
about 4 minutes. Then, refined wheat flour is dropped in step-by-step manner and final mixing
is done for about 6 minutes. After, preparation of the sponge, the dough is loaded in the trolleys
and left for fermentation for about 18-24 hours. The sponge is prepared at the rate of about 4
batches/day. It is taken in a specified amount with entire batch of slurry for the preparation of
dough.
 c) FINAL DOUGH PREPARATION:
The dough is prepared by mixing the single batch of slurry, 36.3 kg
of fermented sponge dough and all the other ingredients. The mixing process takes about 20
minutes of the time and the final dough is unloaded and feed in the hopper for the further
processes which leads to sheeting, lamination and cutting into desired shapes.

2. FROM DOUGH-TO-DOUGH PIECES:

The prepared dough is fed into the hopper, which is made
into thick sheets by the thresh sheeter, reduced to thin sheets by the set of gauge rollers. Then,
it reaches the cut & lay laminator and made into several layers of lamination. Again, the
laminated sheets were made into thin sheets by passing into series of gauge rollers and cut into
desired shape by the Rotary Cutter. After, the cut dough pieces were taken into oven wire band
and passed on to oven for baking process.
The steps involved between the dough feeding into hopper to the final cut dough pieces were
listed below:

i. Hopper
ii. Thresh sheeter
iii. Pre-gauge roller - 1
iv. Pre-gauge conveyor
v. Pre-gauge roller – 2
vi. Cut & lay laminator
vii. Conveyor – 1
viii. Gauge roller – 1
ix. Gauge roller conveyor – 1
x. Gauge roller – 2
xi. Gauge roller conveyor – 2
xii. Final gauge roller
xiii. Relaxation
xiv. Rotary cutter
xv. Cutting web
xvi. Oven band

3. BAKING SECTION:
The dough pieces are carried by the iron band into the oven. The baking
process is carried into the continuous baking oven with six zones of operation. The temperature
range between the zones is about 180-310°C. The baking time takes about 4 minutes 15 secs.
After the baking process, the biscuits were taken for the oil spray immediately after leaving the
oven. Then, it is left to cooling before packing through the cooling conveyor.

4. COOLING AND PACKING SECTION:

The biscuits will be soft after coming out from the oven and needed to
cooled down to attain the desired texture. After, leaving the cooling conveyor the biscuits were
taken into the packing machines. The horizontal form fill machines were used to pack the
biscuits. The ladder setup in the packing machine is adjusted as per required number of pieces
needed in a pack.
 GOOD DAY
MANUFACTURING PROCESS FOR GOOD DAY COOKIES:
1. INGREDIENTS USED:
Refined wheat flour, Palm Oil, Invert Syrup, Butter, Salt Water, Water,
Lecithin, DMG Paste, DATEM Biscuit Powder, Ammonium Bicarbonate, Montreal Sugar,
Sodium Bicarbonate, Flavors (Good Day Cashew & Butter) and Processed Dust.

2. CREAM PREPARATION:
The cream is prepared initially in the mixing tank by mixing all the
ingredients other than the ammonia (added directly into the pre-creamer tank) and refined
Wheat flour. The mixing is continuously done to keep the cream in pre-creamer tank at the
desired level needed for the production process. After the mixing process, the cream is pumped
into pre-creaming tank, where the ammonia is added. After the proper mixing of ammonia, the
cream is automatically pumped to the holding tank at the required intervals. From the holding
tank, cream is taken into continuous mixer through controlled valves with specific flow volume
controls.

3. CONTINUOUS DOUGH MIXER AND MOULDER:

The prepared cream is mixed with the refined wheat flour at a rate. The
continuous dough mixer has a horizontal screw mixer and the mixed dough is taken into
moulder section, where the biscuits were formed out from the moulding die. In case of good
day Cashew variety, the cashew were mixed in the dough for base and also sprinkled before
moulding to get on top as sprinkles. Then, the moulded dough pieces were taken into oven for
baking.

4. BAKING SECTION:
The dough pieces are carried by the iron band into the oven. The baking
process is carried into the continuous baking oven with six zones of operation. The temperature
range between the zones is about 180-300°C . The baking time takes about 6
minutes.

5. COOLING AND PACKING SECTION:

The biscuits will be soft after coming out from the oven and needed to
cooled down to attain the desired texture. After, leaving the cooling conveyor the biscuits were
taken into the packing machines. The horizontal form fill machines were used to pack the
biscuits. The ladder setup in the packing machine is adjusted as per required number of pieces
needed in a pack.
 MARIE GOLD
MANUFACTURING PROCESS FOR MARIE GOLD BISCUITS:
1. INGREDIENTS USED:
Refined Wheat Flour, Palm Oil, Invert Syrup, Sugar Solution, Water, Salt
Water, Whey Powder, Ammonium Bicarbonate, Bio Bake, Lactose, Calcium Carbonate,
DATEM, Vitamin Premix, Potassium Color Caramel, Ferrous Fumarate, Flavours and
Processed Dust. (For Milk Spray - Water, Color Caramel, Condensed Milk and Flavors).
2. CREAM PREPARATION:
The cream is prepared initially in the mixing tank by mixing all the
ingredients other than the ammonia (added directly into the pre-creamer tank) and refined
Wheat flour. The mixing is continuously done to keep the cream in pre-creamer tank at the
desired level needed for the production process. After the mixing process, the cream is pumped
into pre-creaming tank, where the ammonia is added. After the proper mixing of ammonia, the
cream is automatically pumped to the holding tank at the required intervals. From the holding
tank, cream is taken into continuous mixer through controlled valves with specific flow volume
controls.

3. CONTINUOUS DOUGH MIXER AND SHEETER:

The prepared cream is mixed with the refined wheat flour at a rate. The
continuous dough mixer has a horizontal screw mixer, the mixed dough is taken into horizontal
continuous kneader and conveyed to the sheeter and laminator. The laminated sheets were
pressed and the thickness is reduced to desired level. The sheets were cut into desired shapes
by the use of rotary cutter. The cut dough pieces were given a milk spray on the top to enhance
the color and texture on the surface. The cut dough pieces were then taken into oven for baking
process.

4. BAKING SECTION:
The dough pieces are carried by the iron band into the oven. The baking
process is carried into the continuous baking oven with six zones of operation. The temperature
range between the zones is about 190-315°C. The baking time takes about 4 minutes 30 secs.

5. COOLING AND PACKING SECTION:

The biscuits will be soft after coming out from the oven and needed to
cooled down to attain the desired texture. After, leaving the cooling conveyor the biscuits were
taken into the packing machines. The horizontal form fill machines were used to pack the
biscuits. The ladder setup in the packing machine is adjusted as per required number of pieces
needed in a pack.
 MILK BIKIS
MANUFACTURING PROCESS FOR MILK BIKIS BISCUITS:
1. INGREDIENTS USED:
Refined wheat flour, palm oil, invert syrup, sugar solution, water, whey
powder, Skim milk powder, sweetened condensed milk, potassium water, ammonium
bicarbonate, calcium carbonate, vitamin premix, GMS paste, lecithin and Processed dust.
2. CONTINUOUS DOUGH MIXER AND MOULDER:
The prepared cream is mixed with the refined wheat flour at a rate. The
continuous dough mixer has a horizontal screw mixer and the mixed dough is taken into
moulder section, where the biscuits were formed out from the moulding die. In case of good
day Cashew variety, the cashew were mixed in the dough for base and also sprinkled before
moulding to get on top as sprinkles. Then, the moulded dough pieces were taken into oven for
baking.

3. BAKING SECTION:
The dough pieces are carried by the iron band into the oven. The baking
process is carried into the continuous baking oven with six zones of operation. The temperature
range between the zones is about1 80-300°C. The baking time takes about 4 minutes 30 secs.

4. COOLING AND PACKING SECTION:

The biscuits will be soft after coming out from the oven and needed to
cooled down to attain the desired texture. After, leaving the cooling conveyor the biscuits were
taken into the packing machines. The horizontal form fill machines were used to pack the
biscuits. The ladder setup in the packing machine is adjusted as per required number of pieces
needed in a pack.
 QUALITY WALL

➢ A wall is quality Tool which acts as an enabler to ensure compliance to product

specification.
➢ It is a standardized approach for evaluation and release of finished product
➢ It is an approach for product to be evaluated from a consumer eye and not as a technical
expert
OBJECTIVE

✓ Main objective of this session is to ensure that there is a common approach and
application of the quality wall process across plants
✓ Products qualifying on sensory parameters can cross the wall and get released. In case
of no consensus between members, the analytical data will support the wall process for
a common rating.
TYPES OF MEETINGS

ROUTINE MEETINGS
Conducted (typically) every 4 hours by the team to review the product being made and
take actions, as needed, to ensure compliance to product design specifications.
MINI WALLS
Conducted (typically) within 30 minutes of start-up and at changeover to evaluate
finished product for its acceptability.
HOT WALLS
Conducted within 15 minutes after corrective actions (indicated by a routine Quality
Wall / post abort) has had time to affect finished product.
PARTICIPANTS

❖ Team leader – who organizes quality wall

❖ Operators (mixing to packing)
❖ Quality analysis officers / line inspectors
❖ Production officers
❖ Production & quality managers
❖ Plant manager
THE GOLD STANDARD

Gold standard

Market Competition
sample market sample

GOLD STANDARD =BEST ON ALL PARAMETRS

Sensory evaluation based on 07 parameters

➢ Smell
➢ Texture
➢ Taste
➢ Flavour
➢ Swallowing
➢ Appearance / visual admiration
➢ Overall feeling

COLOUR

1. Rejected pale
2. Acceptable pale
3. Standard colour
4. Acceptable dark
5. Rejectable dark
RECORDS FOLLOWED

1. Quality wall record

2. CCP monitoring record
3. Recipe record
4. Operational pre requisites
5. Conveyor condition monitoring
6. Online quality checks
7. Online moisture record
8. Coding checking note
9. DQI observation
10. Product parameters measurement
11. Leak test note
12. Pack weight record-Milk Bikis
13. Pack weight record-Good Day
14. Pack weight record-50-50
15. Pack weight record-Marie Gold
EVALUATION

Sensory Evaluation Rating Scale / Action Plan

Products with Gold Standard Reference
Score Rating Definition
0 Exact match to reference
1 Green Very close to reference.
Requires Reference to detect
difference.
2 Close to Reference. Experts
may or may not detect
Yellow take action difference from Reference
when evaluating without
using reference.
3 Clearly different from
Yellow take action Reference. It is a minimum
score of 3 or higher for
texture.
4 Severely different from
Red abort Reference. Violates one or
more product design
attributes.

Sensory Evaluation Rating Scale / Action Plan

Products with Gold Standard Reference
Rating BIL Definition
Go Exact match or very close to
0-1 design. Most consumers
would be unable to detect
difference from design.
Go take action Clearly different from
2-3 design. Most consumers
would detect a difference
from design.
No go Severely different from
4 design. Violates one or more
product design attributes.
Standard moisture:

LSL MEAN USL CORRECTION

FACTOR
MRG 1 1.25 1.5 0.1
GDY 1.5 1.75 2.0 GDC-0.14,
GDB-0.21
5050 1.45 1.70 1.95 0.25
MBK 1 1.25 1.5 0.09

Variety SKU No. of biscuits. Standard weight/packet Declared weight/ packet

MRG 83 17 85 83
120 25 125 120
200 41 205 200
250 51 255 250
GDC 60 8 61.54 60
100 14 107.69 100
120 16 123.08 120
200 27 207.69 200
GDB 75 10 76.92 75
150 20 153.85 150
250 33 253.85 250
5050 38 12 38.65 38
76 24 77.29 76
150 48 154.59 150
200 64 206.12 200
MBK 40.5 8 41.52 40.5

Particulars MRG GD FF MBK

Baking time 4 min 30 secs 6 mins 4 mins 15 secs 4 mins 30 secs
Dough sponge : 28 to 34
temperature(°C) 34 to 36 30 to 32 dough: 30 to 32 32 to 35
sponge : 18-24 hrs,
Dough standing slurry:1-2 hrs,
time 20 to 40 minutes 0 to 4 minutes dough:20 to 30 minutes 0 to 5 minutes
cooling time 6 mins 45 secs 9 minutes 6 minutes 22 secs 6 minutes 45 secs
seal strength
(g/25mm) Min 550 Min 800 Min 600 Min 1000
 PERSONNEL HYGIENE
➢ All should wear uniform with cap before entering into the manufacturing.
➢ Hands should be washed in soap solution and then IPA solution and Should be dried in
hot air drier.
➢ No material should be kept in top pocket of the coat.
➢ Wearing watches, rings etc., in the processing area should be avoided.
➢ Using of strong perfumes should be avoided.
➢ Rub the foot /footwear in the rubber mat before entering into the processing area.
➢ Person’s with skin diseases should consult the medical center.
➢ Smoking, chewing of betel vine is strictly prohibited.
➢ Drinking beverages inside the processing area is prohibited.

MEDICAL CENTRE
Medical is the first aid Centre present inside the campus.
The main function of Medical is to maintain the health record of all employees in BIL. Any
person who is going to be appointed should have a medical check up here before. Physically
fit persons are admitted into the company. Contract workers also have this check up before
entry.
Any employee / worker subjected to sudden accident inside the company is given first aid and
if needed recommended to hospital. Medicines are provided at free of cost for maximum 2 days
if there is any indisposition.
 MAINTENANCE DEPARTMENT
Maintenance Department includes packing, general and electrical maintenance. All the
officers from the maintenance will have specific work. Maintenance Engineers are responsible
for this dept.
Packing Department:
The function of packing maintenance is to maintain all the packing machines in good condition.
They should clean and maintain the machines with proper lubrication. every week. And also
they should attend the problem during the shift also.
Also, packing maintenance take incharge of changing the conveyors, belt. bearings etc.
Maintenance Officers immediately attend the problem during packing.
General Maintenance :
General maintenance section takes incharge of maintaining the oven and mixing They have to
attend the preventive problem in week end and breakdown problem during shift. Daily, the
maintenance officer will go a round from mixing to oven end to see the condition of all
machines. If there is any noise in machines, they should attend it. If they found any wear and
tear, they have to note it and should minimise it in the week end.
Steam for standards department to use in Kettle is provided from Boiler Maintenance
Department is responsible for Boiler operation and they are responsible for Water softening
plant is in the company, which supply water for all purposes. They maintain the records for all
repairs. They are having some schedule for all machines and they have to check the machines
as per the schedule in week end.
 ENGINEERING STORES

Engineering stores is a part of BIL which consists of all engineering related

materials like bearings, nuts, bolts, rubber rolls, motors, electrical accessories etc. Here,
hygiene related materials like soaps, brooms, soap solutions are stored and delivered to the
cleaning department. In Engineering stores, only new items are stored and delivered. The worn
out and repaired items will not come under Engineering stores.

Functions of Engineering Stores:

First the department which needs engineering parts will produce a purchase requisition letter.
This letter is sent to Engineering stores. The stores officer will inform this to the Purchase
Department and the purchase department will make a order to the concern company. The
materials received from the company is unloaded in the stores and checked by stores workman
and then stored and delivered whenever necessary. Stores will produce a goods received (GR)
form and sent this to the Accounts Department. The payment for the concerned company will
be settled by the accounts department. The above procedure is the specific materials which is
not available in the engineering stores. Generally, all the spare parts are available in the stores.
Any department which needs the spare parts from the stores will fill the requisition form the
stores will fill the requisition form and take the required materials.
PROJECT: STABILIZATION OF DOUGH MOISTURE
PROBLEM STATEMENT:
The moisture content of finished product is beyond the standard limit. Due to high moisture,
the finished products may influence microbial population and will affect the texture of the
biscuits. Also, results in consumer complaints.
CORRECTIVE ACTION:
The parameters contributing to moisture changes should be monitored in every stage of
processing. The steps must be taken to gradually decrease the dough moisture without affecting
the product quality.
WORK DONE:
To reduce moisture content in the dough, the moisture contributing factors were
monitored and relevant data has been collected for the analysis. The data collected were
• Flour characteristics – moisture content, Gluten value and Sedimentation value
• Dough ingredients – Cream percentage, Ammonia, Dust, Water and equivalent weight.
• Oven profile – Zone temperatures, Baking time, RPM and Blower levels.
• Moisture Analysis – Dough and Finished Good moisture.
 MOISTURE PARAMETERS (MRG) - 09.07.2021

FLOUR CHARACTERISTICS
BRAND MOISTURE CONTENT(%) SEDIMENTATION VALUE(%) GLUTEN(%)
PRESSANA 13.17 21.56 9.49
NARASUS 13.25 20.58 9.24

DUST WATER BAKING TIME DOUGH MOISTURE

TIME CREAM(%) (KG) (KG) (MIN) CONTENT

11.30 83 60 46 4.45 22.10

2.30 83 60 46 4.55
4.00 83 60 46 4.45
5.00 83 60 46 4.45

MOISTURE CONTENT
ZONE -1 ZONE - 2 ZONE -3 ZONE -4 ZONE -5 ZONE - 6 RPM (%)
TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM
192 219 287 293 299 299 294 298 290 293 289 291 44.1 2.3
190 224 288 294 300 300 295 299 290 293 288 291 42.2 1.92
191 234 289 295 300 301 296 299 290 294 289 292 42.2 2.37
190 234 287 293 300 298 294 299 288 293 288 289 42.7 2.68
 MOISTURE PARAMETERS (MRG) – 10.07.2021

MAIDA WET BAKING

TIME LINE GLUTEN SV CREAM DUST WATER
MOISTURE MOISTURE TIME
10.00 MRG 13.47 9.28% 22.54% 84 60 47 21.13 5.05
11.00 MRG 13.47 9.28% 22.54% 84 60 47 20.94 5.05
12.00 MRG 13.47 9.28% 22.54% 84 60 47 20.85 5.05
13.00 MRG 13.47 9.28% 22.54% 84 60 47 5.00
14.00 MRG 13.47 9.81% 21.78% 84 60 47 5.00
15.00 MRG 13.47 9.81% 21.78% 85 60 47 5.05
16.00 MRG 13.47 9.81% 21.78% 85 60 47 5.05
17.00 MRG 13.47 9.81% 21.78% 85 60 47 4.55

ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 DRY

RPM
TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM MOISTURE
192 233 281 286 292 292 287 289 282 285 280 282 39 2.08
190 224 281 285 291 291 286 289 282 285 285 283 39 2.13
190 231 280 284 290 289 285 287 281 283 279 281 39 2.28
190 230 276 281 286 286 281 284 278 281 278 279 39 2.42
189 224 273 276 282 281 277 280 274 276 272 274 39 2.87
189 227 272 277 282 282 277 280 273 276 272 274 39.5 2.31
190 228 270 273 279 278 274 276 271 273 268 271 39.2 2.42
190 230 270 274 280 279 276 278 274 276 273 275 37 2.14
 MOISTURE PARAMETERS (MRG) - 12.07.2021

MAIDA WET BAKING

TIME LINE GLUTEN SV CREAM DUST WATER
MOISTURE MOISTURE TIME
10.00 MRG 13.47 9.28% 22.54% 85 60 49 20.49 4.28
11.00 MRG 13.47 9.28% 22.54% 85 60 49 21.11 4.35
12.00 MRG 13.47 9.28% 22.54% 85 60 49 21.35 4.3
13.00 MRG 13.47 9.28% 22.54% 85 60 49 4.3
14.00 MRG 13.87 9.81% 21.78% 85 60 49 4.35
15.00 MRG 13.87 9.81% 21.78% 85 60 49 4.35
16.00 MRG 13.87 9.81% 21.78% 85 60 49 4.35
17.00 MRG 13.87 9.81% 21.78% 85 60 49 4.35

ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 5 ZONE 6 DRY

RPM
TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM MOISTURE
193 237 293 298 303 304 297 303 295 299 294 296 44 3.73
190 236 293 299 304 305 297 308 295 300 295 297 43 3.03
189 220 294 299 305 304 299 304 296 300 296 297 44.2 3.7
192 233 293 299 305 305 300 303 296 298 295 296 44.6 3
190 218 293 299 305 305 301 304 297 299 295 296 43.7 2.09
192 237 293 299 303 304 299 304 296 298 294 295 44.2 2.64
191 231 293 299 304 304 298 304 296 299 295 296 42.7 2.53
191 236 293 299 304 304 298 303 295 299 294 298 41.5 2.45
 MOISTURE PARAMETERS (MRG&GDY) - 13.07.2021

FLOUR CHARACTERISTICS
SILO BRAND BATCH NO MOISTURE CONTENT(%) SEDIMENTATION VALUE(%) GLUTEN(%)
NARASUS 910 13.49 19.6 9.73
MEENAKSHI G 09 13.87 19.8 9.98
NARASUS BULK 911 13.27 19.6 9.17

SILO -1
MEENAKSHI G 11 13.86 20.79 9.76
SAHUWALA G 09 13.78 20.79 9.08
SAHUWALA G 10 13.84 23.76 9.38

SILO - 3
SAHUWALA G 11 13.78 19.8 9.67

TIME CREAM(%) DUST (KG) WATER (KG) AMMONIA EQUIVALENT WEIGHT DOUGH MOISTURE CONTENT

10.00 89 60 49 9.7 5
11.10 86 60 49 9.0 5 21.57
12.15 86 60 49 9.0 5 21.44

BAKING TIME (MIN) ZONE -1 ZONE - 2 ZONE -3 ZONE -4 ZONE -5 ZONE - 6 RPM
TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM
4.30 190 234 295 300 304 305 300 304 296 299 295 296 44.9
4.30 190 232 295 299 305 305 298 303 296 297 295 297 44.7
4.30 192 227 293 298 304 304 305 299 304 299 294 295 45.4
 MOISTURE PARAMETERS (MRG) - 14.07.2021

FLOUR CHARACTERISTICS
SILO BRAND BATCH NO MOISTURE CONTENT(%) SEDIMENTATION VALUE(%) GLUTEN(%)
SILO -1 NARASUS 911 13.27 19.6 9.17
SILO - 3 SAHUWALA G12 13.89 20.79 9.22

DOUGH MOISTURE
TIME CREAM(%) DUST (KG) WATER (KG) AMMONIA(KG) (%) BAKING TIME (MIN)

10.58 86 60 48 9 21.43 4.35

12.02 86 60 48 9 22.03 4.40
1.10 86 60 48 9 22.20 4.35
3.00 86 60 46 9 4.35
4.10 83 20 27 7 4.35
5.10 83 20 27 7 4.35

MOISTURE CONTENT
ZONE -1 ZONE - 2 ZONE -3 ZONE -4 ZONE -5 ZONE - 6 RPM (%)
TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM
191 229 292 298 305 304 298 304 295 298 293 296 41.9 2.81
190 235 293 299 305 307 299 304 294 300 294 296 41.9 2.87
190 236 292 299 304 306 297 304 295 300 295 298 41.9 2.95
189 229 293 299 304 305 296 303 295 299 295 298 40.3 2.6
191 237 293 298 304 305 300 302 296 299 295 296 40.3 2.35
190 231 293 299 305 304 298 303 296 299 294 297 40.3 2.43
 MOISTURE PARAMETERS (GDY) - 14.07.2021

DOUGH MOISTURE
TIME CREAM(%) DUST (KG) WATER (KG) AMMONIA (%) BAKING TIME (MIN)

11.00 111 60 54 2.5 14.19 6.00

12.00 111 60 54 2.5 13.93 6.00
1.10 111 60 54 2.5 13.4 5.55
3.10 112 60 54 2.5 5.50
4.15 113 60 54 2.5 5.50
5.10 115 60 54 2.5 5.50

MOISTURE CONTENT
ZONE -1 ZONE - 2 ZONE -3 ZONE -4 ZONE -5 ZONE - 6 RPM (%)
TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM TOP BOTTOM
222 311 254 291 299 302 300 304 295 304 291 298 12.7 2.86
222 311 254 291 300 304 300 305 295 305 288 298 13.23 2.94
222 311 254 289 299 301 299 304 294 305 288 299 13.07 2.74
221 311 255 291 299 303 300 304 293 300 290 290 12.7 2.92
220 312 254 292 300 302 301 304 294 301 288 298 12.7 2.47
219 312 256 292 301 302 300 304 294 301 289 300 12.7 2.75
 15-7-21-OVEN VS MOISTURE ANALYSER

MOISTURE ANALYSER @ 1040

0
OVEN METHOD @ 105 c - 4 HRS C
DISH + SAMPLE FINAL WEIGHT
BISCUIT EMPTY DISH WEIGHT(G) (G) (G) MOISTURE CONTENT (%) MOISTURE CONTENT (%)

MBK 89.088 103.06 102.821 1.71 2.01

50-50 82.288 95.508 95.2 2.33 3.08

DOUGH CONSISTENCY 50-50

TIME DOUGH MIXER -1 TIME DOUGH MIXER -2
2.55 254 3.05 256
3.30 250 3.30 255
3.45 251 3.53 253
 16-7-21-oven temperature & blower profile

BLOWER VALVE PROFILE

50 50 GDY MRG MBK

TOP 212 263 191 228
ZONE 1
BOTTOM 191 246 236 239
TOP 274 217 291 261
ZONE 2
BOTTOM 225 300 298 287
TOP 276 298 303 305
ZONE 3
BOTTOM 264 300 304 300
TOP 249 300 297 306
ZONE 4
BOTTOM 305 302 302 294
TOP 284 294 294 302
ZONE 5
BOTTOM 305 290 299 301
TOP 301 288 292 300
ZONE 6
BOTTOM 304 299 296 300

VALVE % 0 0 0 0
B1
RPM NA 45 30 50
VALVE % 0 0 0 40
B2
RPM NA 40 30 NA
VALVE % 0
B3
RPM 40
191 228
 16-7-21- Leakage study

LEAKAGE TEST - MACHINE NO.202 TEMPERATURE PROFILE OF ROLLERS AND JAWS

TIME SAMPLE SIZE BUBBLES LEAK REMARKS PACKAGE MANUFACTURER RL1 LS1 RL2 UJ1 LJ1 UJ2
3.35 5 4 0 ADITHYA FLEXI PACK SV 185 160 185 120 123 120
5 2 0 ADITHYA FLEXI PACK PV 185 160 185 120 123 120
4.44 5 4 2 LONG SEAL-1, ADITHYA FLEXI PACK SV 185 160 185 120 123 120
5 2 0 END SEAL -1 ADITHYA FLEXI PACK PV 181 159 184 120 123 120
5.04 5 4 2 END SEAL ADITHYA FLEXI PACK SV 185 160 185 120 123 120
5 3 2 ADITHYA FLEXI PACK PV 185 160 185 120 123 120

LEAKAGE TEST - MACHINE NO.203 TEMPERATURE PROFILE OF ROLLERS AND JAWS

TIME SAMPLE SIZE BUBBLES LEAK REMARKS PACKAGE MANUFACTURER RL1 LS1 RL2 UJ1 LJ1 UJ2
3.34 5 3 2 END SEAL -3, ADITHYA FLEXI PACK SV 195 100 185 120 120 128
5 2 2 LONG SEAL -1 ADITHYA FLEXI PACK PV 195 100 185 126 127 128
4.04 5 2 0 ADITHYA FLEXI PACK SV 195 100 185 128 125 128
5 2 0 ADITHYA FLEXI PACK PV 195 100 184 128 127 128
4.27 5 2 0 ADITHYA FLEXI PACK SV 195 100 185 128 125 128
5 2 1 END SEAL - 1 ADITHYA FLEXI PACK PV 196 100 185 128 129 128
5.03 5 1 0 ADITHYA FLEXI PACK SV 195 100 185 128 125 128
5 1 0 ADITHYA FLEXI PACK PV 196 100 184 128 124 128
 Oven vs Moisture analyser (19-7-21)

OVEN VS MOISTURE ANALYSER

OVEN METHOD @ 1050c - 4 HRS MOISTURE ANALYSER @ 1040 C
TIME BISCUIT EMPTY DISH WEIGHT(G) DISH + SAMPLE (G) FINAL WEIGHT (G) MOISTURE CONTENT (%) MOISTURE CONTENT (%)

11.1 MRG 91.452 103.41 103.21 1.67 2.09

12 MRG 76.766 89.02 88.75 2.20 2.65
MRG 87.586 99.611 99.413 1.65 1.9
12.45
GDY 92.24 104.626 104.376 2.02 2.46

Oven vs Moisture analyser (20-7-21)

OVEN VS MOISTURE ANALYSER

OVEN METHOD @ 1050c - 4 HRS MOISTURE ANALYSER @ 1040 C
TIME BISCUIT EMPTY DISH WEIGHT(G) DISH + SAMPLE (G) FINAL WEIGHT (G) MOISTURE CONTENT (%) MOISTURE CONTENT (%)
GDY 87.71 99.716 99.457 2.157254706 2.61
10.30
MRG 81.662 93.031 92.868 1.433723283 1.82
GDY 86.808 98.173 97.948 1.979762429 2.21
12.00
MRG 31.126 43.384 43.207 1.443954968 2.02
 RESULTS & DISCUSSIONS:
The collected data were analysed and the following suggestions were made to
reduce the moisture content of finished goods.
✓ The moisture in dough can be brought down by reducing the input water.
✓ The moisture content in the dust and the scrapped dough should be monitored and
taken into account.
✓ Operating the oven under standardised RPM, baking time and the temperature helps
us to maintain the moisture content of finished goods.
✓ The dough weight on the working and non-working side should be maintained evenly
by continuously monitoring the cutter/moulder arrangements.
✓ The final moisture content can be controlled by decreasing the input moisture.
✓ The initial moisture content of the dough is contributed by various ingredients such as
invert syrup, salt solution, sugar solution and other ingredients with mixture of water.
By reducing the quantity of water in these ingredients in a step-by-step manner, will
help us to reduce the moisture content in the dough and ultimately reduces the
moisture content in the finished product.
 INDUSTRY LAYOUT

BRITANNIA INDUSTRIES LTD

SIPCOT, PERUNDURAI
ERODE
FACTORY CODE: 9C
 CONCLUSION

The world today is moving at a fast phase and the competition is high. The quest to learn
something more is never ending. However, practical experience is one of the best way to learn.
In this sort period of training, we have acquired a detailed idea of how biscuit industry works,
including Time Management, which is crucial.

The training has given us a realisation of how important the tinniest of details are and how
much work and sweat goes into success of such a company, the days that we have spent here
taught us this and lot more. We have tried to work to the best of our capacities and to learn the
maximum possible. The secret to our contentment and happiness for the successful completion
of this internship lies in the fact that this learning process have been a very pleasurable one.

With excellent cooperation from all staff, we could understand the entire process at
considerable ease, which will stand in “good stead” in our career path.

We once again thank our college, The Management and The Staff at all level for giving us a
wonderful opportunity and invaluable and rare exposure to this industry.