H.

IQBAL FOOD INDUSTRIES FAISALABAD

BY

Simra Abbas
D/O
Muhammad Abbas

FOOD SCIENCE AND TECHNOLOGY

DEPARTMENT OF FOOD SCIENCE AND TECHNOLOGY FAISALABAD

PAKISTAN
2024

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 DEDICATION
At first, dedicating this work to Allah without his sympathy and mercy, I was not able to
complete this work. Almighty Allah gave me the confidence and power to complete my thesis
and also the Holy Prophet Hazrat Muhammad (PBUH), who illuminated humanity.
I also dedicate this work to my wonderful mother, who has inspired me to pursue higher goals in
life. I also thanked them for their prayers, sacrifice, supporting me through thick and thin, and
their endless patience. They are “Heaven on Earth” for me.

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It is certified that Simra Abbas, FST-4th RIUF has successfully completed her internship at H. Iqbal food
industry Faisalabad from 01-08-24 to 18-09-24.The contents and form of this report has been found
satisfactory and recommended that it will be processed for the award of degree.

Internship station supervisors

Organizational Supervisor

H. IQBAL Food Industries pvt. Ltd Farooq Ijaz (Owner)

Internship Station Supervisor

H. IQBAL Food Industries pvt. Ltd Mr. IKRAM SHAHZAD

Quality Assurance Officer

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 ACKNOWLEDGEMENT
Allah is the one who creates the entire universe and human to explore his creation. I thank to Almighty
Allah for the countless mercy He took on me, the help, the power, the courage, and whatever he bestowed
upon me for the completion of my task and making it easier for me. I acknowledge my deepest sense of
gratitude for whom this world has been made. The Holy Prophet (PBUH) who had spread the light of
learning in the world and forever city of knowledge for the whole humanity. I am also thankfull to my
friends and family members who were my supporter throughout my educational career. I owe a great debt
of gratitude to honorable Sir Ikram Shahzad (Quality Assurance Officer) for their valuable
guidance and inspiring attitude during my internship. I pay thanks to all member of industry. Besides,
this internship program makes me realize the value of working together as a team and as a new
experience in working environment, which challenges us every minute. All praise to my parents and
siblings for their love, appreciations which always stand by me mentally and spiritually during all years of
my study. May Allah give them a long and happy life. Ameen

Simra Abbas

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 TITLE
ACKNOWLEDGEMENT
TABLE OF CONTENTS
INTRODUCTION TO INTERNSHIP PROGRAM

1.1 Objective
1.2 Benefits
1.3 Advantages
INTRODUCTION TO H. IQBAL FOOD INDUSTRIES

2.1 Introduction
2.2 Mission
DEPARTMENTS IN INDUSTRY
3.1. Chocolate department
3.1.1. Bubble chocolate
3.1.2. Daylite chocolate
3.1.3. Bike chocolate
3.1.4. Jeep chocolate
3.1.5. Catbery chocolate

3.2. Candy department

3.2.1. Rain bow lollipop
3.2.2. King pop lollipop
3.2.3. Little pop lollipop
3.2.4. Merga pop lollipop
3.2.5. Bang pop lollipop

3.3. Toffee department

3.3.1. Sparak toffee
3.3.2. Jubilee toffee
3.3.3. Sixer toffee
3.3.4. Peanut toffee
3.3.5. Makhani toffee
 Fast football Bubble Gum department
1. Boom boom
2. Little olive bubble gum
3. Super goal bubble gum
4. Elachi bubble gum
5. Fish bubble gum

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CANDY MANUFACTURING
Fast Football Bubble Gum Manufacturing
Recommendation
Summary of Internship

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CHAPTER NO. 01

INTRODUCTION TO INTERNSHIP PROGRAM

An internship is a short-term, entry-level role that can help you gain skills and
knowledge in a specific field
1.1 Objective

Internship program is designed in order to equip the students with practical knowledge and
expertise which couldn’t be achived without exposure to field and research organization .

1.2 Benefits

Internship is a kind of program which strongly enhances the expertise and practical approach on
various aspects of agricultural research. It makes a student more inclined towards achieving the
new horizons in agricultural research. It helps in broadening the vision of students.

Following are some of its major advantages:

 The best thing about this program is that we get practical know how about the theoretical
knowledge which we have gained our degree program
 It makes a student more ready to face daily problems of agriculture research and solving
these problems more rationally and prudently
 Internship also helps us in interacting with scientists, which helps us in sharing new ideas
and development

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CHAPTER NO. 02

INTRODUCTION TO H. IQBAL FOOD INDUSTRIES

INTRODUCTION

H. Iqbal Food Industries is a prominent player in the food manufacturing and processing
sector, recognized for its commitment to delivering high-quality food products. Established with
the vision of providing nutritious and delicious options, the company has built a solid reputation
in the industry.

Core Offerings:

1. Diverse Product Range: H. Iqbal Food Industries offers a wide array of food products,
which may include packaged snacks, ready-to-eat meals, and other processed food items.
Their portfolio often features products catering to various tastes and dietary needs.

2. Quality Assurance: The company prioritizes quality control and adheres to stringent
standards to ensure that every product meets or exceeds industry benchmarks. This
commitment to quality is reflected in their manufacturing processes and ingredient
selection.

3. Innovation and Development: Embracing technological advancements and consumer

trends, H. Iqbal Food Industries continually innovates to bring new and improved
products to the market. Their research and development efforts focus on enhancing taste,
nutrition, and convenience.

4. Customer-Centric Approach: With a focus on meeting consumer preferences and

needs, the company strives to deliver products that align with market demands and
lifestyle trends. They often engage in market research to better understand and serve their
customer base.

Mission and Vision:

 Mission: To deliver high-quality and innovative food products that enhance the culinary
experience while maintaining rigorous standards of hygiene and safety.

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  Vision: To be a leading food industry player recognized for excellence, innovation, and
sustainability, contributing positively to the communities they serve.

Commitment to Sustainability:

H. Iqbal Food Industries is also committed to sustainable practices, incorporating

environmentally friendly processes and sourcing methods. This commitment helps in reducing
their environmental footprint and promoting sustainable development in the food industry.

Community and Market Presence:

With a strong presence in the market, H. Iqbal Food Industries aims to build lasting relationships
with consumers, distributors, and stakeholders. Their community engagement initiatives often
focus on supporting local causes and contributing to social development.

If you have specific details or aspects about H. Iqbal Food Industries that you'd like to include or
elaborate on, feel free to share!

Figure 1 Industry Building

CHAPTER NO 03.
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 DEPARTMENTS IN INDUSTRY
1. Chocolate Department

2. Candy Department
3. Toffee Department
4. Bubble Gum Department
5. Coating Department

6. Molding Department

Industry products with varieties:

1. Candy
 Rain bow lollipop
 King pop lollipop
 Merga pop lollipop
 Bang pop lollipop
 Little pop lollipop

2. Toffee
 Sparak toffee
 Jubilee toffee
 Sixer toffee
 Peanut toffee
 Makhani toffee

3. Bubble gum
 Boom boom
 Little olive bubble gum

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CHAPTER NO. 04

CANDY MANUFACTURING

Candy manufacturing is a fascinating field that blends science, art, and commerce to produce a
wide range of confectionery products enjoyed by people around the world. Here’s an
introduction to the candy manufacturing industry:

Introduction to Candy Manufacturing

Candy manufacturing is the process of creating various types of sweet confections, including
candies, chocolates, gummies, and other sugary treats. This industry combines traditional recipes
with modern technology to produce a diverse array of products that cater to different tastes and
preferences.

Core Aspects of Candy Manufacturing

1. Raw Materials:
o Sugar: The primary ingredient in most candies, which can be sourced from
sugarcane or sugar beets.
o Sweeteners: Additional sweeteners such as corn syrup, glucose, and honey are
used to enhance sweetness and texture.
o Flavorings: Natural and artificial flavors are added to create a wide variety of
tastes.
o Colorants: Food-grade colors are used to make candies visually appealing.
o Texturizers: Ingredients like gelatin, pectin, and starch are used to modify the
texture of candies.
2. Production Processes:
o Mixing: Ingredients are combined to form a mixture or dough. This step is crucial
for ensuring a consistent product.
o Cooking: The mixture is heated to specific temperatures to achieve the desired
consistency and texture. This process can vary depending on the type of candy
being produced.
o Molding and Shaping: The cooked candy is poured into molds or shaped into
different forms, such as bars, pieces, or gummies.
o Cooling and Setting: The candy is cooled and allowed to set, which can take
place in temperature-controlled environments.
o Packaging: Finished candies are packaged for distribution. Packaging is designed
to maintain freshness, prevent contamination, and attract consumers.
3. Types of Candy:
o Hard Candies: Examples include lollipops, peppermint sticks, and jawbreakers.

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 oSoft Candies: Such as gummies, marshmallows, and nougat.
oChocolate: Includes milk chocolate, dark chocolate, and chocolate-covered
candies.
o Caramels and Toffees: Made with a combination of sugar, butter, and cream.
o Chewy Candies: Like taffy and licorice.
4. Quality Control:
o Testing: Regular testing is conducted to ensure that candies meet quality
standards for taste, texture, and safety.
o Compliance: Manufacturers must adhere to food safety regulations and
standards, which include proper labeling and hygiene practices.
5. Innovation:
o Product Development: Candy manufacturers continuously innovate by
experimenting with new flavors, textures, and packaging designs to meet
consumer preferences and market trends.
o Technology: Advances in technology, such as automated production lines and
sophisticated mixing equipment, enhance efficiency and consistency in candy
manufacturing.
6. Market and Distribution:
o Retail: Candies are sold through various retail channels, including supermarkets,
specialty stores, and online platforms.
o Global Reach: Many candy manufacturers export their products worldwide,
catering to international markets and diverse consumer tastes.

Industry Trends

 Health-Conscious Choices: There is a growing demand for candies made with natural
ingredients, reduced sugar, or functional benefits (e.g., added vitamins).
 Sustainability: Many manufacturers are adopting sustainable practices, such as using
eco-friendly packaging and sourcing ingredients responsibly.
 Customization: Personalized and artisanal candies are gaining popularity, offering
unique flavors and custom designs.

Conclusion

Candy manufacturing is a dynamic and creative industry that combines traditional confectionery
techniques with modern advancements to produce a wide range of delightful treats. From
sourcing raw materials to innovative product development and global distribution, the industry
continuously evolves to satisfy the ever-changing tastes and preferences of consumers.

4.2 Difference between candy and toffee

Candy is a confection whose primary ingredient Toffee is a type of hard but chewy candy
is sugar. Candy includes various sweet made of sugar and butter. Toffee is made
confections such as hard candy, soft candy, taffy, by caramelizing sugar or molasses with
marshmallow, and caramels. Sugar is the butter. Sometimes ingredients such as
common feature in all these products. The main nuts, raisin, and flour are added to this

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 characteristic of candy is the significant amount mixture. At the hard crack stage, the toffee
of sugar or sugar substitutes used in its mixture will have a glossy surface, but it
production. Candy is also typically made as small will be stiff enough to be made into
pieces. Candy can give food energy, but it different shapes. The mixture is then
typically has no other nutritional value beyond poured into a tray and left to cool and
energy. It is considered as a source of empty form a slab. Toffee is brown in color due
calories. to the effects of caramelization.

4.3 Store Room Standards

 Distance from ingredients to wall
 Distance from ingredient to ingredient
 Light should be proper
 All products must be tagged
 Products must be labeled
 IPM ( integrated pest management)

4.4 Kitchen equipment’s

 Dissolver
 Backup container
 Cooker
 Cooling table
 Aging machine

4.5 Raw material of candy with quantity

 Distilled water 10L
 Sugar 250kg
 Glucose Liquid 220kg
 Citric acid 300g
 Artificial Flavor’s 500ml
 Food grade color 200g

4.6 Procedure
Firstly, we add distilled water in dissolver and then add sugar and allow to mix well then we add
liquid glucose and cook on 100C. After cooking candy dough shift to cooling table and allow to

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cool after cooling then pass to aging machine. After aging the dough set on the molder to mold
the shape of candy.
4.7 Flow diagram of candy

4.8 Sources of Raw material in candy

Sources of Raw Materials in Candy Manufacturing

1. Sugar

 Source: Sugar is primarily derived from two plants:

o Sugarcane: Grown in tropical and subtropical regions, such as Brazil, India, and
China.
o Sugar Beets: Cultivated in temperate regions like the United States, Europe, and
Russia.
 Forms Used: Granulated sugar, powdered sugar, brown sugar, and liquid forms like
molasses.

2. Sweeteners

 Corn Syrup: Produced from corn starch through hydrolysis. It is a common sweetener in
candies and is sourced from corn grown in the U.S. and other major corn-producing
countries.
 High-Fructose Corn Syrup (HFCS): Made by further processing corn syrup to increase
its fructose content. Also predominantly sourced from corn.
 Honey: A natural sweetener produced by bees from nectar. Sourced from beekeepers
globally.
 Maple Syrup: Derived from the sap of sugar maple trees, mainly produced in Canada
and the northeastern United States.
 Agave Syrup: Extracted from the agave plant, primarily grown in Mexico.

3. Flavorings

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  Natural Flavors: Extracted from fruits, spices, herbs, and other natural sources. For
example, vanilla is extracted from vanilla beans, while citrus flavors come from fruits
like oranges and lemons.
 Artificial Flavors: Synthesized in laboratories to replicate natural flavors. Commonly
used due to cost-effectiveness and consistency.
 Essential Oils: Concentrated extracts from plants, such as peppermint oil or citrus oils.

4. Colorants

 Natural Colorants: Derived from fruits, vegetables, and other plant sources. For
instance, beet juice can be used for red coloring, and spirulina for blue-green hues.
 Artificial Colorants: Synthetic dyes like Red 40 or Yellow 5, used to achieve vibrant
and consistent colors.

5. Texturizers

 Gelatin: Derived from animal collagen, usually obtained from the bones, skin, and
connective tissues of cows and pigs. Produced through a hydrolysis process.
 Pectin: A natural gelling agent extracted from fruits, particularly apples and citrus fruits.
Used in products like gummies and jellies.
 Starch: Sourced from corn, potatoes, or tapioca. Modified starches are used to control
texture and consistency in candies.

Functions of Raw Material

1. Distilled water:
There are many excellent reasons for using distilled water in food preparation. Preparing
food with distilled water not only improves the taste of any kind of food but also its
safety nutrition and appearance because distilled water is such an excellent solvent.
2. Sugar:
In confectionary products sugar contributes to texture and structure of traditional
products.
3. Liquid Glucose:
Use of glucose syrup in production of hard and soft candy results in higher plasticity of
the candy affects durability of color and taste add clarity and shine.
4. Citric Acid:
Because of its acidic sour tasting nature , citric acid is predominantly used as a flavoring
and preserving agents especially in candies.
5. Artificial flavor:
Artificial flavors are additives designed to mimic the taste of natural ingredients.
Artificial flavor is simply to impart sensory pleasure to a good taste.
6. Food Grade Color:

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 Color additives are used in foods for many reasons including to make food more
attractive, appealing, appetizing and informative but offsetting color loss over time due to
exposure to light, air and storage conditions.
Equipment:
 Extruder
 Batch ruler
 Sizer machine
 Universal plant
 Molding dye
 Conveyer belt
 Siever
4.11 Function of equipment
1. Extruder : Used to fill the bubble gum in lollypop
2. Batch ruler : Convert dough into rope shape
3. Sizer machine : Used to control size and weight
4. Universal plant: Add any dye and found shape
5. Molding dye: Shape out the product
6. Conveyer belt: Convey product to siever
7. Siever: Remove extra product and stable to cool down

4.12 Packaging area

Equipment:
 Packing machine
 Weighing balance
 Sealer
 Holer
 Binding machine
 Tape machine

Packing material:
 Wrapper
 Pouch
 Jar
 Boxes
 Cartons
 Stickers
 Tape
 Binding tape

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4.13 Types of packaging
1. Primary packaging
2. Secondary packaging
3. Tertiary packaging

1. Primary packaging: Primary packaging is a packaging in direct contact with the product
itself.

2. Secondary packaging: Secondary packaging is an additional layer that protects products,

holds them together and optimizes them for transport. It offer

3. Tertiary packaging: Tertiary packaging is the third level of three types of packaging used
to protect manufactured goods for shipping or storage

Primary packaging First wrap of any product is primary packaging

Standards:
 Wrapper should be food grade
 Ingredients should be mentioned
 Product name should be mentioned
 Manufacturing address should be mentioned
 Wrapper should be free from any hole
 Avoid to pass air in packaging

Secondary packaging packing in jars boxes pouches

Standards:
 Price should be mentioned
 Raw material should be highlighted
 Manufacturing date should be mentioned
 Batch No should be mentioned
 Expiry date should be mentioned
 Net weight should be mentioned
 Gross weight Should be mentioned
 Logo should be printed

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Tertiary packaging packed in cartons

Standards:
 Product name should be mentioned
 Address should be listed
 Expiry date should be mentioned
 Batch No should be mentioned
 Net weight, gross weight should be highlighted
 Instruction should be mentioned
 Quality should be mentioned

4.14 Storage Area

Standards:
 Area should be neat and clean
 Cartoon should be place in sequence
 More than 5 cartons are be in lined
 IPM installed
 Distance between walls and finished product should be maintained
 Room temperature should be 25 °C

4.15 Sanitation and personal hygiene

Standards:
 Flour sanitation
 Wall sanitation
 Spider net remove
 Machine should be neat and clean
 Trays should be proper washed

Personal hygiene

Standards:
 Nails should be short and clean
 Wear clogs and safety shoes
 No wrist wash and rings
 Wear neat and clean clothes
 Cap, mask and gloves should be worn

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CHAPTER NO. 5

FAST FOOTBALL BUBBLE GUM MANUFACTURING

Introduction
Bubble gum in many forms has existed since the Neolithic period. 5,000-year-old chewing gum
made from birch bark tar, with tooth imprints, has been found in Kierikki in Finland. The tar
from which the gums were made is believed to have antiseptic properties and other medicinal
benefits. It is chemically similar to petroleum tar and is in this way different from most other
early gum. The Mayans and Aztecs were the first to exploit the positive properties of gum. They
used chicle, a natural tree gum, as a base for making a gum-like substance and to stick objects
together in everyday use. Forms of chewing gum were also chewed in Ancient Greece. The
Ancient Greeks chewed mastic gum, made from the resin of the mastic tree. Mastic gum, like
birch bark tar, has antiseptic properties and is believed to have been used to maintain oral health.
Both chicle and mastic are tree resins. Many other cultures have chewed gum-like substances
made from plants, grasses, and resins. Although chewing gum can be traced back to civilizations
worldwide, the modernization and commercialization of this product mainly took place in the
United States. The American Indians chewed resin made from the sap of spruce trees.

Fast Football Bubble gum Manufacturing:

The manufacture of football-themed bubble gum involves several key steps:

1:Formulation:
Create a gum base with ingredients such as natural or synthetic rubbers,
sweeteners, flavorings, and colorings. The formulation should reflect the desired
taste and texture.
2. Mixing:
Blend the gum base with flavorings and colorings. This mixture is then heated and
mixed thoroughly to ensure even distribution of ingredients.
3.Extrusion:
The blended gum is fed into an extruder, which shapes it into long strips. These
strips are then cut into smaller pieces or formed into football shapes.
4.Coating:
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If the gum is to be coated (e.g., with a candy shell), it's done through a coating
machine that applies layers of sugar or other coating ingredients.
5.Packaging:
The finished gum pieces are packaged in wrappers or containers, often featuring
football-related designs or branding.
6.Quality Control:
Throughout the process, quality checks are performed to ensure consistency in
flavor, texture, and appearance.
If you're looking to start a football-themed bubble gum business, you'll need to
address not just manufacturing but also branding, distribution, and compliance
with food safety regulations.
Store Room Standards
 Distance from ingredients to wall
 Distance from ingredient to ingredient
 Light should be proper
 All products must be tagged
 Products must be labeled
 IPM ( integrated pest management)
Kitchen equipment’s
 Mixer
 Grinder machine
 Weighing
 Cutter
Raw material of Bubble gum with quantity
 Liquid glucose 18kg
 Gum base 7kg
 Telcom powder 7kg
 Sugar 50kg
 Citric acid (optional)
 Artificial flavor 250ml
Procedure
Add glucose in the mixer after heating the glucose then add gum base in paste form. After adding
the gum base add telcom powder add sugar in the mixture. Citric acid is optional if sour gum is
produced. In last add artificial flavor for giving the unique flavor.

Flow diagram of bubble gum

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5.7 Sources of Raw material in bubble gum
1. Liquid Glucose:
Liquid glucose is one of the popular food additives and ingredient in most countries.
Corn syrup or liquid glucose is made from high quality corn starch by subjecting starch to
high temperature in the presence of acids under strict quality control.
2. Sugar:
Cane sugar , beet sugar and high fructose corn syrup cane sugar is processed into raw sugar by
a sequence of operations harvesting, cutting, crushing, extraction of juice, clarification,
evaporation , crystallization, centrifugation and refining.
3. Gum base:
Gum base is made of polymers plasticizers and resins. Polymers including elastomers are
responsible for the stretchy and sticky nature of bubble gum. Plasticizers improves flexibility
and reduce brittleness contributing to the plastic and elastic nature of gum.
4. Telcom powder:
Talc is a naturally occurring mineral mined from the earth composed of
magnesium, silicon, oxygen, and hydrogen.
5. Citric Acid:
Citric acid is a weak organic acid found in the greatest amount in citric fruits, such as
lemon grapefruit, orange.
6. Artificial flavors:

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 Artificial flavor comes from petroleum and other inedible substances.
5.8 Functions of Raw Material
1. Liquid glucose
Liquid glucose syrup is used in production of bubble gum.
Glucose syrup is a non-crystallizing substance. It is commonly
used in chewing gum. Liquid glucose ensure good preservative
qualities, enhanced shelf life and smooth texture of the product.
2. Gum Base
Gum base is the non-nutritive, non-digestible, water insoluble
masticatory delivery system used to carry sweeteners, flavors and any other substances in
chewing gum and bubble gum. It provides all the basic textural and masticatory properties of
gum.
3. Telcom powder
Talc is soft, innocuous and organophilic, making it an ideal
functional fillers in chewing gum bases for fruity and non-fruity
flavors. Talc imparts excellent rheology and mouth feel to the
gum base. Talc is also an ideal anti-stick powdering agent
preventing gum sticks from adhering to wrapper.
4. Sugar
Most of the flavors in gum is due to the sugar which dissolves in
saliva and is swallowed never to be tasted again. The size of a
wad of gum decrease considerably in the first 10-15 minutes of chewing. This change in
volume is due to lose of sugar.
5. Citric acid
A common ingredient in chewing gum and other confectionary is citric acid it gives the
sharp, refreshing citric taste. Because of its acidic sour tasting nature that gives the sourness
to product.

6. Artifical flavor
Artificial flavor is used to give mouth feel flavor that enhance the taste of bubble.
5.9 Molding Area
Equipment:
 Extruder
 Conveyer belt
 Sizer machine
 Universal plant
 Molding dye
 Chiller Figure 2. Bubble Dough
 Plastic trays
 Air bowls
5.10 Function of equipment
1. Extruder : convert dough into rope shape
2. Conveyer belt : to move the dough in next point with minimal effort
3. Sizer machine : Used to control size and weight

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Figure 3. Checked Roped shape of bubble
 4. Universal plant: Add any dye and found shape
5. Molding dye: Shape out the product
6. Air blows : Too cool down the batch
7. Chiller : Too maintain the temperature
8. Trays: Stable the product in trays

5.11 Procedure
After cook or prepared the batch convey to the conveyer belt then cut the pieces. Extruder
convert the dough in rope shape. After rope shape conveyer belt convert the dough to sizer
machine. Sizer machine control the weight.

5.12 Coating Area

Equipment:
 Cooking pan
Figure 4. Checked the shape of bubble
 Coating pan
 Buckets
 Bowls
 Weighing balance
 Air blowers
 Chillers

Figure 5. Checked the coating of bubble

5.13 Coating Material

 Sugar 50kg
 Liquid glucose 2kg
 Distilled water 10L
 Food grade color 200g

How to prepare the coating material?

Making syrup: first we take a pan and add water in it. Boil the
water and add sugar and melt down the sugar then add glucose in it
and heat at 100C . After heating cool down the syrup.

How coat the product?

Feed the product in coating pan. Carnuba wax is used for product
shinning polish the wax to shine the product.
5.14 Packaging area
Equipment:
 Pillow wrap machine
 Weighing balance
 Sealer
 Binding machine
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  Tape machine

Packing material:
 Wrapper
 Pouch
 Jar
 Boxes
 Cartons
 Stickers
 Tape
 Binding tape

5.15 Types of packaging

4. Primary packaging
5. Secondary packaging
6. Tertiary packaging

1. Primary packaging: Primary packaging is a packaging in direct contact with the product
itself.

2. Secondary packaging: Secondary packaging is an additional layer that protects products,

holds them together and optimizes them for transport. It offer

3. Tertiary packaging: Tertiary packaging is the third level of three types of packaging used
to protect manufactured goods for shipping or storage

Primary packaging First wrap of any product is primary packaging

Standards:
 Wrapper should be food grade
 Ingredients should be mentioned
 Product name should be mentioned
 Manufacturing address should be mentioned
 Wrapper should be free from any hole
 Avoid to pass air in packaging

Secondary packaging packing in jars boxes pouches

Standards:
 Price should be mentioned
24
  Raw material should be highlighted
 Manufacturing date should be mentioned
 Batch No should be mentioned
 Expiry date should be mentioned
 Net weight should be mentioned
 Gross weight Should be mentioned
 Logo should be printed

Tertiary packaging packed in cartons

Standards:
 Product name should be mentioned
 Address should be listed
 Expiry date should be mentioned
 Batch No should be mentioned
 Net weight, gross weight should be highlighted
 Instruction should be mentioned
 Quality should be mentioned

5.16 Storage Area

Standards:
 Area should be neat and clean
 Cartoon should be place in sequence
 More than 5 cartons are be in lined
 IPM installed
 Distance between walls and finished product should be maintained
 Room temperature should be 25 °C

5.17 Sanitation and personal hygiene

Standards:
 Flour sanitation
 Wall sanitation
 Spider net remove
 Machine should be neat and clean
 Trays should be proper washed

Personal hygiene

25
Standards:
 Nails should be short and clean
 Wear clogs and safety shoes
 No wrist wash and rings
 Wear neat and clean clothes
 Cap, mask and gloves should be worn
 Wound cover with a plaster or bandage

CHAPTER NO 6
TOFFEE MANUFACTURING
6.1 Introduction
Toffee is called soft boiled confectionery made by sugar along with butter and milk. It is popular
among young and also with the children. Toffee is a confection made by caramelizing sugar or
molasses (creating inverted sugar) along with butter, and occasionally flour. The mixture is
heated until its temperature reaches the hard crack stage of 300 to 310 °F (149 to 154 °C). While
being prepared, toffee is sometimes mixed with nuts or raisins. Toffee used in confectionery has
many different forms and is mixed with many different ingredients: Rum & Butter Toffee,
Chocolate Covered, Vanilla & Chocolate, Rum & Raisin, and Honeycomb. The process of
making toffee involves boiling the ingredients until the mix is stiff enough to be pulled into a
shape which holds and has a glossy surface. The resulting mixture will typically be poured into a
shallow tray and allowed to cool to form a sheet. Different mixes, processes, and (most
importantly) temperatures of toffee making will result in different textures and hardnesses, from
soft and often sticky to a hard brittle material. Milk toffee is a mass consumption item and these
toffees are not very costly and therefore, easily affordable in rural areas. Hard Candy
manufacturing business is an economically viable and financially profitable business. Toffees
and candies are mostly produced for local market; the volume was around 12,000 metric tons for
the year 2003. Toffee is made out of fruit pulps and has ingredients like skimmed milk powder,
glucose and sugars in different flavors. Fruit toffees have good demand in cities, urban and semi-
urban areas and institutions. The business idea is premised on production of 208,000 fruit toffees
per month which translates into 2,496.000 fruit toffees per year. In India Hard-boiled candy is

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reserved for the small-scale sector. There are about 5,000 units catering to the local markets.
Sugar-boiled confectionery, consisting of hard-boiled candy, toffees and other sugar-based
candies, is the largest of the segments and, according to some key industry players we spoke to,
it is valued at around rs. 20,000 million. US candy manufacturers offer a wide range of products
and have a huge presence in the global market. This is due to the growing consumer demand for
sweets. Toffees and candies are consumed both in rural and urban areas without any exception.

6.2 Store Room Standards

 Distance from ingredients to wall
 Distance from ingredient to ingredient
 Light should be proper
 All products must be tagged
 Products must be labeled
 IPM ( integrated pest management)

6.3 Kitchen equipment’s

 Dissolver
 Mixer
 Weighing balance
 Cooking pan

6.4 Raw material of toffee with quantity

 Distilled water 10L
 Sugar 250kg
 Glucose Liquid 17kg
 Flour 7kg
 Artificial Flavor’s 250ml
 Vanilla powder 200g
6.6 Procedure
Firstly, we add distilled water in dissolver and then add sugar and allow to mix well then we add
liquid glucose and cook on 130C and place syrup into dissolver then add flour and allow to
mixing the dough. In last add vanilla powder and mix it well.
6.7 Flow diagram of toffee

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6.8 Sources of Raw material in toffee

1. Distilled water:
Distilled water is purified water produced by condensing steam or water vapors from
impure water such as well water, sea water, tap water, snow streams, or even plants or
damp rock.
2. Sugar:
Cane sugar , beet sugar and high fructose corn syrup cane sugar is processed into raw
sugar by a sequence of operations harvesting, cutting, crushing, extraction of juice,
clarification , evaporation , crystallization, centrifugation and refining.
3. Liquid Glucose:
Liquid glucose is one of the popular food additives and ingredient in most countries.
Corn syrup or liquid glucose is made from high quality corn starch by subjecting starch to
high temperature in the presence of acids under strict quality control.
4. Artificial flavors:
Artificial flavor comes from petroleum and other inedible substances.
5. Flour:
Although usually derived from wheat flour can also be milled from almond, coconut,
millet, oat, corn, rice rye, sorghum, soy etc

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 6. Vanilla powder:
First off, a vanilla bean is no bean—it's actually the fruit of orchids in the genus Vanilla.
Those vanilla orchids only grow in a very small subsection of the world, with Madagascar
producing a whopping 80%.

6.9 Functions of Raw Material

1. Distilled water:
There are many excellent reasons for using distilled water in food preparation. Preparing
food with distilled water not only improves the taste of any kind of food but also its
safety nutrition and appearance because distilled water is such an excellent solvent.
2. Sugar:
In confectionary products sugar contributes to texture and structure of traditional
products.
3. Liquid Glucose:
Use of glucose syrup in production of hard and soft
candy results in higher plasticity of the candy affects
durability of color and taste add clarity and shine.
4. Artificial flavor:
Artificial flavors are additives designed to mimic the
taste of natural ingredients. A Artificial flavor is
simply to impart sensory pleasure to a good taste.
5. Vanilla powder:
Vanilla is particularly useful for baking because of its
rich base note flavor. Vanilla plays the same role in sweet foods as salt does in savoury. It
adds its own distinct flavor while enhancing those of other ingredients.

6. Flour:
Typical functional properties include emulsification, hydration (water binding viscosity)
solubility, gelation, cohesion, and adhering.
6.10 Molding Area
Equipment:
 Ruler
 Aging table
 Cutter

Procedure
Mix raw material in mixer then convert the dough to aging machine and cut into loaf and pass
through the ruler. Ruler is used to flat the dough and stable to cool down and pass through the
cutter in horizontal and vertical direction.
6.11 Coating Area
Equipment:
 Coating pan
 Cooking pan

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  Bowls
 Buckets
Coating material with quantity
 Sugar 50kg
 Distilled Water 5l
 Glucose 2kg
 Chocolate color 300g
 Cocoa powder 1kg

How to prepare the coating material?

Making syrup: first we take a pan and add water in it. Boil the water and add sugar and melt
down the sugar then add glucose in it and heat at 100C . After heating cool down the syrup.

How coat the product?

Feed the product in coating pan. Carnuba wax is used for product shinning polish the wax to
shine the product.

Coating of chocolate
Ingredients:
 Fat 25kg
 Powder milk 5kg
 Cocoa powder 10kg
 Sugar 50kg
 Artificial flavor 250ml
 Color 200g

Procedure:
In pan, melt the fat and add sugar in grind form add milk powder then add cocoa powder and mix
all the ingredients well and then add artificial flavor. Making the material then roaber machine is
used for coating the chocolate.
6.12 Packaging area
Equipment:
 Pillow wrap machine
 Weighing balance
 Sealer
 Binding machine
 Tape machine

Packing material:
 Wrapper

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  Pouch
 Jar
 Boxes
 Cartons
 Stickers
 Tape
 Binding tape

6.13 Types of packaging

7. Primary packaging
8. Secondary packaging
9. Tertiary packaging

1. Primary packaging: Primary packaging is a packaging in direct contact with the product
itself.

2. Secondary packaging: Secondary packaging is an

additional layer that protects products, holds them together and
optimizes them for transport. It offer

3. Tertiary packaging: Tertiary packaging is the third

level of three types of packaging used to protect manufactured
goods for shipping or storage

Primary packaging First wrap of any product is primary packaging

Standards:
 Wrapper should be food grade
 Ingredients should be mentioned
 Product name should be mentioned
 Manufacturing address should be mentioned
 Wrapper should be free from any hole
 Avoid to pass air in packaging
Figure 7.Primary packaging
Secondary packaging packing in jars boxes pouches

Standards:
 Price should be mentioned

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  Raw material should be highlighted
 Manufacturing date should be mentioned
 Batch No should be mentioned
 Expiry date should be mentioned
 Net weight should be mentioned
 Gross weight Should be mentioned
 Logo should be printed

Tertiary packaging packed in cartons

Standards:
 Product name should be mentioned
 Address should be listed
 Expiry date should be mentioned
 Batch No should be mentioned
 Net weight, gross weight should be highlighted
 Instruction should be mentioned
 Quality should be mentioned

Storage Area

Standards:
 Area should be neat and clean
 Cartoon should be place in sequence
 More than 5 cartons are be in lined
 IPM installed Figure 9 Visited storage area
 Distance between walls and finished product should be
maintained
 Room temperature should be 25 °C

6.14 Sanitation and personal hygiene

Standards:
 Flour sanitation
 Wall sanitation
 Spider net remove
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  Machine should be neat and clean
 Trays should be proper washed

Personal hygiene

Standards:
 Nails should be short and clean
 Wear clogs and safety shoes
 No wrist wash and rings
 Wear neat and clean clothes
 Cap, mask and gloves should be worn
 Wound cover with a plaster or bandage

Recommendations
GMP' (Good manufacturing practices) should be followed

 Equipment maintenance
 Main cleanliness
 Pest control
 Raw material control
 Ensuring food safety
 Improving product quality
 Training and education
 Personal hygiene
 Sanitary facilities

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Summary of internship:

I have learned many skills during my internship program at H.IQBAL, H.IQBAL also makes me
able to complete the task efficiently. H.IQBAL has good management communication policies
and standard of work which makes the H.IQBAL work environment better. Freshness of product
is quality of H.IQBAL which gives high market share to the industry. During my internship
program I've concluded that H.IQBAL has hardworking employees and highly committed
management and this gives success to H.IQBAL INDUSTRY. Due to unstable economy of
Pakistan, the prices of everything go very high and this is the main factor which reduces the
efficiency of H.IQBAL. Although the profit is gradually increased every year but it is because of
H.IQBAL team effort which give consistent quality and also new product every year. H.IQBAL
always focuses on the satisfaction of is customer which is the passive point of this organization.

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