CHAPTER 2 :- PRODUCTION

DEPARTMENT

Chapter Index:-
2.1 RAW MATERIALS:- .............................................................................................................. 14
2.2 HEAVY MACHINERIES:- ....................................................................................................... 14
2.3 PLANT LAYOUT:- ................................................................................................................. 16
2.4 PRODUCTION SYSTEM:- ....................................................................................................... 20
2.5 PRODUCTION PROCESS:- ..................................................................................................... 21
2.6 MATERIAL HANDLING EQUIPMENT:- ................................................................................... 26
2.7 INVENTORY CONTROL METHODS:- ...................................................................................... 27
2.8 ORDER QUANTITY:- ............................................................................................................ 27
2.9 LEAD TIME:- ....................................................................................................................... 28
2.10 REORDERING LEVEL:- ....................................................................................................... 29
2.11 INSPECTION AND QUALITY CONTROL TECHNIQUES:- ........................................................ 30
2.12 TRAINING:- ....................................................................................................................... 32
2.13 PRODUCTS AND SERVICES:- ............................................................................................... 32

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Production:
Production is the transformation process that turns resources into valuable goods or
services. Imagine it as combining raw materials, plans, and know-how to create something
useful. These outputs can be physical products or intangible services that improve our lives.

2.1 RAW MATERIALS:-

• Vegetables
• Dairy Products
• Food Grains
• Spices
• Dry fruits
• Flour

2.2 HEAVY MACHINERIES:-

1. Kettles
Figure 2.1: Kettle

An industrial cooking kettle is a heavy-duty piece of equipment used in commercial

kitchens. It typically has a capacity of around 500 litres, suitable for large-scale cooking
operations. These kettles are designed to withstand high temperatures and are often
equipped with features like agitation or tilting mechanisms to facilitate
mixing and pouring.

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2. Oil Heating tank
Figure 2.2: Heating Tank

Oil Heating tanks play a crucial role in ensuring efficient and controlled heating processes
in industrial settings. In the food industry, heating tanks are used for cooking,
pasteurization, and sterilization of food products.

3. Blast Room
Figure 2.3: Blast Room

Blast room means an enclosure, for which the doorway and internal space is large enough
for a person to step inside, primarily intended to rapidly cool hot foodstuffs to below 10 °C
in the case of chilling and below – 18 °C in the case of freezing.

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 4. Freeze Dryer
Figure 2.4: Freeze Dryer Machine Figure 2.5: Control Panel

Industrial freeze dryers leverage a process known as sublimation for food preservation.
This technique removes moisture from the product by directly converting ice crystals into
vapor under controlled low pressure and temperature. By bypassing the liquid phase, freeze
drying safeguards its nutritional value and flavour profile. This translates to extended shelf
life for the product while maintaining its original qualities.

2.3 PLANT LAYOUT:-

The production unit utilizes a process layout, strategically grouping equipment and
personnel based on their functions across three distinct levels. This method promotes
efficiency by optimizing resource allocation.

Second Floor:
This floor serves a dual purpose: storing raw materials and facilitating the initial
cooking stage. Dedicated machinery expedites bulk preparation, while a designated
quality control area ensures adherence to rigorous food safety standards. Processed
goods are then transferred to the first floor for further refinement. Additionally, two
cold storage rooms are situated on this floor.

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First Floor:
This floor houses a dedicated area for loading and unloading materials, alongside a blast
freezer and the facility's most prominent freeze dryer. These resources contribute to the
freeze-drying process. Furthermore, a designated packaging area efficiently prepares
products for market. Separate storage areas for both finished goods and packaging
supplies ensure organization and inventory control.

Ground Floor:
This floor supplements the freeze-drying operations with three additional freeze dryers
and a blast freezer. A separate packaging area caters to the packaging needs on this
floor. Essential administrative functions are also housed here, including various
workspaces, a reception area, and storage rooms.

Employee Facilities and Safety Measures:

Each floor prioritizes employee well-being with designated washing areas and separate
changing rooms for male and female staff. Fire extinguishers, clearly marked
emergency exits, and other safety precautions are strategically placed throughout the
facility to guarantee a safe working environment.

Plant layout for First and ground floor is as follows:-

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2.4 PRODUCTION SYSTEM:-
A production system is the heart of any organization that creates products or delivers
services. It's the intricate network that transforms resources into useful goods and services,
adding value to the final product. This value addition can take many forms, such as
increased functionality, improved aesthetics, or enhanced convenience for the consumer.
Given the diverse range of products and services offered by this production unit, an
Intermittent Production System is ideally suited. This system leverages a flexible approach,
utilizing various processes and departments as needed to achieve product diversification.

Chart 2.1: Classification Of Production System

Intermittent System

Job Shop Production System Batch Production

1. Job Shop Production system

• A job shop is a manufacturing system that handles custom or semi-custom
manufacturing processes, such as small to medium-size customer orders.
• In this production unit, Customization is available as per the requirements of
individual customers as well as third party production.
• They also provide service of dehydrating homemade food made without the usage
of oil.
• For example, dehydration of certain third-party products, here the production unit
provides a service of dehydrating the huge amount of food provided by the third
party.

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 2. Batch Production system
• Batch production is a method whereby a group of identical products are produced
simultaneously (rather than one at a time).
• This allows them to fulfil orders in a timely manner. They work closely with
retailers to understand market trends, enabling them to offer a diverse range of
products to meet customer needs.
• This type of system can produce different products like Pav Bhaji and Dal Makhani
in separate batches because it requires different cooking process and processing
time.
• It also produces various products per specific recipe given by the third party that
exports it.

2.5 PRODUCTION PROCESS:-

1. Acquisition and storage of Raw Materials:
• The production unit prioritizes a controlled acquisition process for its raw materials.
Bi-weekly orders ensure optimal inventory levels and freshness for consistent
production quality. Figure 2.6: Color-Coding Chart
• To further ensure quality, a "First In, First Out" (FIFO)
inventory management system is employed, prioritizing
the use of older stock and minimizing waste. For ease
of use within the production process, raw materials are
also color-coded, simplifying identification and
reducing the risk of errors.
• Finally, a multi-level approval process ensures
responsible cost control. Orders require signatures from
the supervisor, department head, and factory head.
• The unit boasts dedicated storage solutions, with
vegetables and dairy products kept in designated cold storage for optimal freshness and
adherence to safety regulations.
• Dry goods have a separate, temperature-controlled storage room to ensure proper
preservation throughout their shelf life.

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2. Cooking process
• A head chef, along with two assistants, oversees the daily cooking operations,
determining specific processes based on the production schedule.
• Five industrial kettles, each with a capacity of 500 kg, facilitate large-batch cooking.
• Each kettle boasts its own dedicated heating tank filled with oil. This independent
system allows for precise temperature control for each kettle, ensuring optimal cooking
conditions for different recipes.

Figure 2.7: Kettle Figure 2.8: Oil Heating Tank

• The oil in each dedicated heating tank circulates through a jacket surrounding its
respective kettle. This indirect heating method provides consistent and efficient heat
distribution throughout the food, promoting better quality and potentially reducing
cooking times.

• In addition to the kettles, various other machines are utilized to streamline the cooking
process, including equipment for boiling, cutting, and peeling. This ensures efficient
preparation and handling of ingredients.

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 • Rigorous Quality Control: After each batch is cooked, a small sample is taken for
comprehensive quality inspection. This inspection utilizes a variety of techniques, such
as water Total Dissolved Solids (TDS) measurement, salt analysis, and sensory
evaluation.
• Importantly, no preservatives are added to the food during this stage.

3. Loading and Unloading

Figure 2.9: Trolley
• If the batch successfully passes quality control, it is
transferred to a designated loading and unloading
room. This room is meticulously maintained at a cool
18°C (64.4°F) to safeguard food safety and prevent
spoilage.
• Within the controlled-temperature room, the cooked
food is carefully portioned onto a series of stainless-
steel trays. These trays, each with a capacity of 3.5 kg
(7.7 lbs), are chosen specifically for their hygienic
properties, minimizing the risk of food contamination.
• For further processing, pre-determined quantities of
loaded trays are strategically organized and secured onto mobile trolleys. This
optimized loading system facilitates the efficient movement and handling of large
volumes of cooked food throughout the production facility.

4. Blast Room
• The first step in the freeze-drying process is rapid freezing within the blast room. This
specialized freezer acts like a high-performance storage unit, rapidly lowering the
temperature of cooked or fresh produce. This quick freeze is crucial for preserving food
quality.
• The rapid temperature drop helps lock in the food's nutritional values, natural taste and
aroma, ensuring consumers experience the full sensory profile.
• The blast room maintains a precise temperature of -30°C (-22°F) for optimal freezing
conditions.
• The food remains in the blast room for approximately eight hours, ensuring a complete
freeze and preparing it for the next stage of the process.

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 • The production unit contains two spacious blast rooms, each holding up to 160-165
trays (roughly four trolleys), on separate floors, allowing for efficient processing of
large batches.

5. Dehydration of Food
• Freeze Drying is a technique specifically designed to preserve the taste and extend the
shelf life of the cooked food. This critical step takes place within the freeze dryer
machine and it takes an average time period of 16 hours to complete the process.
• Freeze-drying removes moisture from the cooked food, reducing it to less than 10%
while operating at low temperatures. This remarkable process retains up to 95% of the
food's original flavour and nutritional value. Additionally, the dried food becomes
lightweight and easier to transport in large quantities.
• The production unit is equipped with four dedicated freeze dryers, each catering to
different processing needs.
o Two machines boast impressive capacities of 600 kg and 150 kg respectively.
These are fully automated, autonomously regulating temperature and time
cycles for optimal results.
o The remaining two dryers have a 60 kg capacity and require hourly supervision
during operation. However, all four machines operate continuously, ensuring
efficient processing around the clock.

Figure 2.10: Freeze Dryer Machine

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6. Quality Checking
To ensure the safety and quality of dehydrated food after moisture removal, a series of tests
are crucial. These analyses act as control measures by:
• Identifying potential spoilage: Tests like pH analysis and water activity (indirectly
measured through TDS) help identify conditions that Favor microbial growth,
ensuring the final product is safe for consumption.
• Maintaining sensory characteristics: Analyses like salt analysis and sensory
evaluation ensure the dehydrated food retains its desired taste, aroma, texture, and
colour after rehydration.
By implementing these control measures through tests like pH analysis, water TDS, salt
analysis, and sensory evaluation, researchers and producers can guarantee consistent
quality and minimize risks associated with dehydrated food.
7. Packaging & Labelling
Following freeze-drying, the dehydrated food undergoes a meticulous three-layer
packaging process to ensure quality and prevent spoilage

• Primary Layer
o It consists of an aluminium bag, chosen for its exceptional moisture barrier
properties. This critical layer safeguards the dehydrated food from rehydration
and maintains its long-term stability. A labelled sticker directly affixed to the
bag displays essential information like the product name and handling
precautions.

Figure 2.11: Packaging Box

• Secondary Layer Design
o Secondary packaging
utilizes a cardboard
box. This box not only
offers physical
protection to the inner
aluminium bag during
transport and storage,
but also serves as a
branding platform. The

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 box prominently features the "Seco Delight" brand name alongside detailed
information about the dehydrated food product. This ensures clear
communication to consumers at the point of purchase.

• Tertiary Layer
o For further protection and efficient handling during transport and storage, a
layer of plastic wrap is used to securely bind five packaged boxes together. This
final layer optimizes storage space and simplifies wholesale or bulk distribution.
Currently, the packaging process is manual. The company is actively pursuing automation
to enhance efficiency and elevate production capacity.

The standard production process involves all the steps mentioned previously, from initial
cooking to multi-layered packaging. However, for customized orders, the process can be
streamlined. These customized products skip the initial stages related to retail-ready
batches and focus solely on dehydrating the specific ingredients, blast-freezing them,
performing the freeze-drying process, and finally packaging the finished product.

2.6 MATERIAL HANDLING EQUIPMENT:-

• Lifts: These heavy-duty elevators handle the vertical legwork. They transport large
quantities of raw materials, like grains or flour sacks, from receiving areas to higher
processing floors. Their speed and capacity minimize manual labour and ensure a
steady flow of materials.
• Trolleys: These are mobile platforms for horizontal movement. They handle a wide
range of items, from bulky ingredient sacks to containers filled with goods, across
departments. They come in various configurations and load capacities, with some even
motorized for easier manoeuvring of heavier items.
• Trays: While trolleys manage larger quantities, trays excel at transferring materials
within a production line. Made for easy cleaning and sanitation, they carry ingredients,
semi-finished items, or even final products between individual machines. Their
compact size allows for smooth movement in tight spaces. Some trays can even
integrate with conveyor systems for further automation.

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2.7 INVENTORY CONTROL METHODS:-
This production unit utilizes a manual inventory control system. A designated supervisor
is responsible for:
• Inventory Checks: The supervisor regularly checks and records the stock levels of
all raw materials.
• Inventory Maintenance: They actively manage inventory levels to ensure sufficient
stock for production.
• Inventory Reports: Every 15 days, a detailed report is generated. This report
provides a clear picture of the current stock (available quantity) of each raw material
and identifies any potential shortfalls (required quantity).
• Order Determination: Based on the report's findings, the supervisor determines the
appropriate order quantity for each raw material to maintain smooth production flow.
This system relies on manual data collection and analysis, potentially leading to
inefficiencies or human error. However, it can be a suitable solution for smaller production
units with a limited number of raw materials.

2.8 ORDER QUANTITY:-

For a company producing 1500kg of dehydrated food daily, order quantity is critical. It
ensures:
• Smooth Production: Enough raw materials to avoid stoppages.
• Reduced Costs: Prevents excess inventory and wasted storage space.
• Quality Control: Minimizes risk of spoilage from overstocked materials.
• Cost Savings: Allows for bulk purchase discounts.
By optimizing order quantities, the company balances production needs, minimizes costs,
and maintains high-quality ingredients for consistent products. An estimated Order
Quantity for various inputs are as follows:-
Raw Materials:
• Daily usage: 4500kg (based on 3kg raw materials per 1kg dehydrated food)
• Safety stock: 450kg (10% buffer)
• Order quantity: 4950kg (daily usage + safety stock)
• Order frequency: Bi-Weekly (considering bulk discounts and storage)

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 Packaging Material:
1. Aluminium Bags (Primary Layer):
• Daily Production: 1500 kg
• Dehydrated Food per Bag: 100 gm = 0.1 kg
• Daily Bag Requirement: 15,000 bags
• Order Quantity:
o To ensure uninterrupted production and maintain a buffer, they place a bulk
order of 500,000 bags every month. This quantity factors in their daily usage
and provides a safety stock of 50,000 bags.
2. Cardboard Boxes (Secondary Layer):
• Each aluminium bag requires a separate box.
• Daily Box Requirement: 15,000 boxes
• Order Quantity:
o Similar to aluminium bags, they place a monthly order of 500,000 boxes to
streamline production and maintain a safety stock of 50,000 boxes.
3. Plastic Wrap (Tertiary Layer):
• To efficiently bundle and secure the packaged boxes during storage and
transportation, this production unit utilizes approximately 540,000 meters of high-
quality plastic wrap per month. The order frequency of this Plastic is monthly.

2.9 LEAD TIME:-

Lead times is a crucial factor in maintaining efficient operations and on-time deliveries.
Lead time refers to the total duration between placing an order for a material and receiving
it at the production facility. Understanding and managing lead times effectively allows the
unit to plan production schedules accurately and avoid delays in the final product delivery.
The research revealed a variance in lead times depending on the material category:
• Pulses: Orders for pulses benefit from a swift turnaround, typically processed within
4-5 days. This short lead time allows for greater flexibility in production planning.
• Vegetables and Dairy Products: Due to the perishable nature of these products, the
production unit maintains a daily procurement schedule. This ensures the freshness
of ingredients used in the final product.
• Packaging Materials: Unlike the other materials, packaging materials have a
significantly longer lead time of approximately two weeks (15 days). This extended

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 lead time necessitates careful planning and coordination between production
scheduling and procurement to ensure a smooth flow of materials and avoid any
potential bottlenecks that could delay the final product delivery.

2.10 REORDERING LEVEL:-

The reorder level (ROL) is the inventory level at which a new order for a particular item
should be placed to ensure there's no stockout before the next delivery arrives. It's a crucial
concept in inventory management, preventing disruptions in production.
Here's how to calculate the reorder level:
ROL = Daily Usage (DU) x Lead Time (LT) + Safety Stock (SS)
Let's break down the components:
• Daily Usage (DU): This is the average daily consumption of the item.
• Lead Time (LT): This is the time it takes for a new order to be delivered, from
placing the order to receiving the stock.
• Safety Stock (SS): This is a buffer of inventory held to account for unexpected
fluctuations in demand or lead time delays.

Some estimated lead times under this production unit:-

• Packaging Material: 15 days
• Pulses, Purées & Spices: 4-5 days (we'll take the average: 4.5 days)
• Vegetables & Dairy Products: Daily (considered 0 days lead time)
Packaging Material:
1. Aluminium Bags (Primary Layer):
o Daily Usage: 15,000 bags
o Lead Time: 15 days
o Safety Stock: 50,000 bags
o Reorder Level: DU * LT + SS = 15,000 * 15 + 50,000 = 275,000 bags
2.Cardboard Boxes (Secondary Layer):
o Daily Usage: 15,000 boxes (Since each bag requires a box)
o Lead Time: 15 days
o Safety Stock: 50,000 boxes
o Reorder Level: DU * LT + SS = 15,000 * 15 + 50,000 = 275,000 boxes

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 3. Plastic Wrap (Tertiary Layer):
o Daily Usage: 540,000 meters / 30 days/month (assuming 30 days in a month) =
18,000 meters/day
o Lead Time: 15 days
o Safety Stock: 60,000 meters
o Reorder Level: DU * LT + SS = 18,000 * 15 + 60,000 = 330,000 meters

Pulses, Purées & Spices:

o Daily Usage: 2000 units (average)
o Lead Time: 4.5 days (average)
o Safety Stock: 400 units
o Reorder Level: DU * LT + SS = 2000 * 4.5 + 400 = 9400 units

Vegetables & Dairy Products:

o Lead Time (LT) = 0 days (daily delivery)
o Since there's no lead time, technically there's no reorder point needed as you can
order more whenever stock runs low. However, a safety stock of 50 units per day is
still maintained.

2.11 INSPECTION AND QUALITY CONTROL TECHNIQUES:-

Various Quality Control inspections and measures are carried out during the whole
production process. These measures are designed to guarantee that the final product meets
all designated safety and quality standards.

1. Pre-Freeze Drying
• Salt Analysis: The concentration of salt is measured to assess the completeness of
the cooking process. A higher salt content can indicate proper cooking, as salt is
less likely to be absorbed by undercooked ingredients.
• pH Test: The pH level of the food is evaluated to ensure it falls within the optimal
range for both safety and flavour profile.

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 • Sensory Analysis: Trained personnel conduct a comprehensive sensory evaluation,
including visual inspection, olfactory assessment (smell), and taste testing to assess
the colour, texture, aroma, and flavour of the cooked food.
• Water Total Dissolved Solids (TDS): The level of dissolved minerals in the
cooking water is measured. Consistent TDS readings indicate controlled cooking
conditions.

2. Outsourced Analysis
• Microbial Testing: External laboratories conduct this test to verify the absence of
harmful bacteria and pathogens in the product.
• Moisture Testing: An external laboratory performs this analysis to confirm the
final moisture content, a critical factor for long-term shelf life and product stability.

3. Post-Freeze Drying
• Sensory Analysis: The final product undergoes another sensory evaluation, including
visual inspection, olfactory assessment, and taste testing to ensure no changes in colour,
texture, aroma, or flavour occurred during the freeze-drying process.
• Water TDS: The level of dissolved minerals is measured again to confirm consistency
after freeze-drying.
• Salt Analysis: Salt content is re-verified to ensure proper retention throughout the
process.
• Microbial Testing (Optional): In special circumstances, manufacturers may perform
additional microbial testing after freeze-drying for heightened safety assurance.

Benefits of these Techniques

The implemented quality control techniques offer several significant benefits:
o Enhanced Food Safety: Regular inspections help identify and eliminate potential
hazards, leading to a safer product.
o Consistent Quality: Maintaining taste, texture, and appearance across production
batches.
o Extended Shelf Life: Verifying proper moisture content ensures optimal product
longevity.

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o Consumer Confidence: Demonstrating a commitment to quality and safety through
rigorous testing.
By combining in-house and outsourced quality control techniques, the production unit can
ensure the production of safe, consistent, and high-quality freeze-dried food products.

2.12 TRAINING:-
The Production Unit prioritizes on-the-job training (OJT) for new employees due to the
specialized nature of freeze-drying. Classroom learning provides a foundation, but true
mastery comes from hands-on experience.
• Immersive Learning: OJT allows trainees to observe and participate in all stages –
from preparation to packaging – under supervisor guidance. This fosters a deep
understanding of the process and the "why" behind each step.
• Optimizing Equipment: Freeze-drying machinery is intricate. OJT provides real-
time experience operating the equipment, ensuring efficient and safe production
practices.
• Quality Control: Trainees actively participate in quality control procedures
alongside experienced personnel. This instils a keen eye for detail and adherence to
strict protocols, vital for consistent product quality.
Overall, OJT empowers new hires with the specialized knowledge and practical skills
necessary to excel in freeze-dried food production. It fosters a culture of collaboration and
ensures the smooth operation of the Production Unit.

2.13 PRODUCTS AND SERVICES:-

• Product Range: This production unit manufactures a variety of ready-to-eat freeze-
dried meals and snacks under the brand name Seco Delights.
• Consumer Services: It provides custom freeze-drying services for individual
customers. This service dehydrates their favourite homemade recipes for long-term
storage.
• Business Services: This production unit offers bulk freeze-drying services for third-
party companies, catering to larger-scale needs.

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• Customization: This production unit can customize freeze-drying processes for
third-party companies to meet specific export requirements, particularly for
destinations like the USA and Canada.

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