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APROJECT REPORT
ONPRODUCTION OF BISCUITS FROM SHORT DOUGH
IMT College of Management amp Higher StudiesK
(Affiliated to Kumaun University)Kashipur Udham Singh Nagar
(UTTARAKHAND)
Submitted By
Mr Arpit NagarBBA ( V )
Roll No 83736
Mr Arpit NagarBBA ( V )
Roll No 83736
Submitted To
Mrs Nimisha agarwalproject co-ordinatorMrs Nimisha agarwalproject co-ordinator
Page 01
Arpits
ACKNOWLEDGEMENT
Preparing a research report is not a single mans efforts It enrich with the joint efforts of those people who share their valuable experience and knowledge
I readily acknowledge my indebtness to my parents whose support dedication and honest efforts have given me an immense help in doing this project
It gives me immense pleasure to express my deep sense of gratitude and appreciation to my external guide Mr Anil Anand (Production Manager Britannia Industries Ltd) for his constant encouragement and valuable suggestions which provided me back bone support in completing this project
I take the opportunity to thank Mr Deepak Dhariyal (Internal Guide) for motivating encouraging and supporting at every step and sparing his valuable time for me
Above all I praise GOD the most beneficial the most merciful that I have been able to complete my training project successfully
ARPIT NAGARBBA (2008-11)
Page 02Arpits
PREFACE
It gives an immense pleasure to present on the topic of Production of Biscuits From Short Dough By the time I completed this project I understood how important it was for a BBA student to do summer training in between the BBA program
I have selected this topic because I was very keen to know about the know how of production system A distinct feature about this project is that it provides a penetrating and comprehensive analysis of all the aspects of production concept and how it defers from bookish knowledge in a simple and lucid style
A project is involving a lot of extensive study and research it also gave me a great deal of exposure to the production department of an industry I hope this project would prove useful to its readers if it deserves
Page 03Arpits
Arpit s
STUDENTS DECLARATION
I Arpit Nagar student of BBA V sem declare that this project report PRODUCTION OF BISCUITS FROM SHORT DOUGH is written and submitted by me under the guidance of Mr Anil Anand (Production Manager Britannia Industries LtdPantnagar) is my original work The entire analysis and conclusion of this report are based on the information which is collected by me during the summer training period
The empirical findings in the report are based on the data collected by myself while preparing this project I have not copied anything from any source (other than provided by the industry officials and website) or any other project submitted for similar purpose
ARPIT NAGARBBA (2008-11)
Page 04
CONTENT SHEET
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S No
Title Page
Acknowledgment
Preface
Students Declaration
Content Sheet
Chapter - 111 Introduction about the project12 Period Of Study13 Company Overview and its Code of
Conduct14 Various Products of Britannia Industries
Ltd
Chapter-221 History of Biscuits22 Production23 Mixing24 Forming25 Baking26 Cooling27 Packaging
Questionnaire (Internal amp External) amp Findings
Bibliography
Copy of the certificate provided by the Britannia Industries Ltd
1
2
3
4
5
6
7
8
9
10
Name of Topic Page No
1
2
3
4
5
6-5167
8-23
24-51
52-8152-5455-7273-7475-7677-78
7980-81
82-92
93
94
As a part of the curriculum of my BBA V semester I undergo a project in Britannia Industries Ltd There I was assigned the project title Production Of Biscuits From Short Dough My topic is concerned with the production system of Britannia Industries through which we can check the various aspects of the production system like the procedure quality measures taken by the company etc
This project work provides me an ample opportunity to judge the companys productivity condition and performance of the workers Through productivity we can evaluate the companys performance in the comparison of other companies accomplishing the same task
Introduction
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stThe period of the study consists of two months from 1 stJuly 2010 to 31 August 2010 in a reputed industrial
organization which is one of the major industries in FMCG sector at Rudrapur-Pantnagar Zone
Address of the company
BRITANNIA INDUSTRIES LIMITEDPLOT N01 SECTOR NO1INTEGRATED INDUSTRIAL ESTATEPANTNAGAR RUDRAPUR-263153Distt UDHAM SINGH NAGARUTTARAKHAND
WEBSITE- wwwbritanniacoin
PeriodOf The Study
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The story of one of Indias favorite brands reads almost like a fairy tale Once upon a time in 1892 to be precise a biscuit company was started in a nondescript house in Calcutta (now Kolkata) with an initial investment of Rs 295 The company we all know as Britannia today
The beginnings might have been humble-the dreams were anything but By 1910 with the advent of electricity Britannia mechanized its operations and in 1921 it became the first company east of the Suez Canal to use imported gas ovens Britannias 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
As time moved on the biscuit market continued to growhellip and Britannia grew along with it In 1975 the Britannia Biscuit Company took over the distribution of biscuits from Parrys who till now distributed Britannia biscuits in India In the subsequent public issue of 1978 Indian shareholding crossed 60 firmly establishing the Indians of the firm The following year Britannia Biscuit Company was re-christened Britannia Industries Limited (BIL) Four years later in 1983 it crossed the Rs 100 crore revenue mark
On the operations front the company was making equally dynamic strides In 1992 it celebrated its Platinum Jubilee In 1997 the company unveiled its new corporate identity
Overveiw of the Company
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Eat Healthy Think Better - and made its first foray into the dairy products market In 1999 the Britannia Khao World Cup Jao promotion further fortified the affinity consumers had with Brand Britannia
Britannia strode into the 21st Century as one of Indias biggest brands and the pre-eminent food brand of the country It was equally recognized for its innovative approach to products and marketing the Lagaan Match was voted Indias most successful promotional activity of the year 2001 while the delicious Britannia 50-50 Maska-Chaska became Indias most successful product launch In 2002 Britannias New Business Division formed a joint venture with Fonterra the worlds second largest Dairy Company and Britannia New Zealand Foods Pvt Ltd was born In recognition of its vision and accelerating graph Forbes Global rated Britannia One amongst the Top 200 Small Companies of the World and The Economic Times pegged Britannia Indias 2nd Most Trusted Brand
Today more than a century after those tentative first steps Britannias fairy tale is not only going strong but blazing new standards and that minuscule initial investment has grown by leaps and bounds to crore of rupees in wealth for Britannias shareholders The companys offerings are spread across the spectrum with products ranging from the healthy and economical Tiger biscuits to the more lifestyle-oriented Milkman Cheese Having succeeded in garnering the trust of almost one-third of Indias one billion population and a strong management at the helm means Britannia will continue to dream big on its path of innovation and quality And millions of consumers will savor the results happily ever after
The Companys head office and registered office and work
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places are located at the below mentioned address
Registered amp Head Office
Britannia Industries Limited51A Hungerford StreetKolkata-700017
Work Places
(a) Britannia Industries Limited33 Industrial AreaLawrance RoadDelhi-110035
(b) Britannia Industries LimitedPlot No-1 Sector No-1Integrated Industrial EstatePantnagar Rudrapur-263153
(c) Britannia Industries Limited15 Taratola RoadKolkata-700088
(d) Britannia Industries LimitedMTH Road PadiChennai-600050
(e) Britannia Industries LimitedReady Road(East) MazagaonMumbai-400010
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BOARD OF DIRECTORS
Name Designation
Mr Nusli Neville Wadia Chairman
Ms Vinita Bali Managing Director
Mr AKHirjee Director
Dr Ajai Puri Director
Mr Avijit Deb Director
Mr Jeh N Wadia Director
Mr Keki Dadiseth Director
Mr Nasser Munjee Director
Mr Ness Nusli Wadia Director
Mr Nimesh N Kampani Director
Mr Pratap Khanna Director
Mr SSKelkar Director
Dr Vijay L Kelkar Director
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Management Team
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Gautam Banarjee General Manager(Materials)
A K Gupta General Manager - Accounts amp Planning
R K Agrawal Supply Chain Director for New Business Development
R S Subramaniam General Manager - Manufacturing Engineering and Projects
Anuradha Narasimhan Category Director - Health amp Wellness
Shalini Degan Category Director - Delight amp Lifestyle
T S Venketram General Manager - Manufacturing Development
Balaji Reddipalli Head Replenishment
R Anand Business Operations Director
Jehanagir Tankariwala General Manager - Human Resources
Vinod Menon Head of BNZF
Shridhar Panshikar National Sales Manager
P Govindan Company Secretary amp Head of Legal
Dr KN Shashikanth Corporate Quality Assurance Manager
V V Padnabham Corporate Manager -Information Systems
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1892 The Genesis - Britannia established with an investment of Rs 295 in Kolkata
1910 Advent of electricity sees operations mechanized 1921 Imported machinery introduced Britannia becomes
the first company East of the Suez to use gas ovens 1939 - 44 Sales rise exponentially to Rs1627202in 1939
During 1944 sales ramp up by more than eight times to reach Rs136 crore
1975 Britannia Biscuit Company takes over biscuit
distribution from Parrys
1978 Public issue - Indian shareholding crosses 60
1979 Re-christened Britannia Industries Ltd (BIL) 1983 Sales cross Rs100 crore 1989 The Executive Office relocated to Bangalore 1992 BIL celebrates its Platinum Jubilee 1993 Wadia Group acquires stake in ABIL UK and
becomes an equal partner with Groupe Danone in BIL
1994 Volumes cross 100000 tons of biscuits 1997 Re-birth - new corporate identity Eat Healthy
Think Better leads to new mission Make every
Milestones for the Company
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third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
Page 20Arpits
companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
ACKNOWLEDGEMENT
Preparing a research report is not a single mans efforts It enrich with the joint efforts of those people who share their valuable experience and knowledge
I readily acknowledge my indebtness to my parents whose support dedication and honest efforts have given me an immense help in doing this project
It gives me immense pleasure to express my deep sense of gratitude and appreciation to my external guide Mr Anil Anand (Production Manager Britannia Industries Ltd) for his constant encouragement and valuable suggestions which provided me back bone support in completing this project
I take the opportunity to thank Mr Deepak Dhariyal (Internal Guide) for motivating encouraging and supporting at every step and sparing his valuable time for me
Above all I praise GOD the most beneficial the most merciful that I have been able to complete my training project successfully
ARPIT NAGARBBA (2008-11)
Page 02Arpits
PREFACE
It gives an immense pleasure to present on the topic of Production of Biscuits From Short Dough By the time I completed this project I understood how important it was for a BBA student to do summer training in between the BBA program
I have selected this topic because I was very keen to know about the know how of production system A distinct feature about this project is that it provides a penetrating and comprehensive analysis of all the aspects of production concept and how it defers from bookish knowledge in a simple and lucid style
A project is involving a lot of extensive study and research it also gave me a great deal of exposure to the production department of an industry I hope this project would prove useful to its readers if it deserves
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Arpit s
STUDENTS DECLARATION
I Arpit Nagar student of BBA V sem declare that this project report PRODUCTION OF BISCUITS FROM SHORT DOUGH is written and submitted by me under the guidance of Mr Anil Anand (Production Manager Britannia Industries LtdPantnagar) is my original work The entire analysis and conclusion of this report are based on the information which is collected by me during the summer training period
The empirical findings in the report are based on the data collected by myself while preparing this project I have not copied anything from any source (other than provided by the industry officials and website) or any other project submitted for similar purpose
ARPIT NAGARBBA (2008-11)
Page 04
CONTENT SHEET
Page 05Arpits
S No
Title Page
Acknowledgment
Preface
Students Declaration
Content Sheet
Chapter - 111 Introduction about the project12 Period Of Study13 Company Overview and its Code of
Conduct14 Various Products of Britannia Industries
Ltd
Chapter-221 History of Biscuits22 Production23 Mixing24 Forming25 Baking26 Cooling27 Packaging
Questionnaire (Internal amp External) amp Findings
Bibliography
Copy of the certificate provided by the Britannia Industries Ltd
1
2
3
4
5
6
7
8
9
10
Name of Topic Page No
1
2
3
4
5
6-5167
8-23
24-51
52-8152-5455-7273-7475-7677-78
7980-81
82-92
93
94
As a part of the curriculum of my BBA V semester I undergo a project in Britannia Industries Ltd There I was assigned the project title Production Of Biscuits From Short Dough My topic is concerned with the production system of Britannia Industries through which we can check the various aspects of the production system like the procedure quality measures taken by the company etc
This project work provides me an ample opportunity to judge the companys productivity condition and performance of the workers Through productivity we can evaluate the companys performance in the comparison of other companies accomplishing the same task
Introduction
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stThe period of the study consists of two months from 1 stJuly 2010 to 31 August 2010 in a reputed industrial
organization which is one of the major industries in FMCG sector at Rudrapur-Pantnagar Zone
Address of the company
BRITANNIA INDUSTRIES LIMITEDPLOT N01 SECTOR NO1INTEGRATED INDUSTRIAL ESTATEPANTNAGAR RUDRAPUR-263153Distt UDHAM SINGH NAGARUTTARAKHAND
WEBSITE- wwwbritanniacoin
PeriodOf The Study
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The story of one of Indias favorite brands reads almost like a fairy tale Once upon a time in 1892 to be precise a biscuit company was started in a nondescript house in Calcutta (now Kolkata) with an initial investment of Rs 295 The company we all know as Britannia today
The beginnings might have been humble-the dreams were anything but By 1910 with the advent of electricity Britannia mechanized its operations and in 1921 it became the first company east of the Suez Canal to use imported gas ovens Britannias 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
As time moved on the biscuit market continued to growhellip and Britannia grew along with it In 1975 the Britannia Biscuit Company took over the distribution of biscuits from Parrys who till now distributed Britannia biscuits in India In the subsequent public issue of 1978 Indian shareholding crossed 60 firmly establishing the Indians of the firm The following year Britannia Biscuit Company was re-christened Britannia Industries Limited (BIL) Four years later in 1983 it crossed the Rs 100 crore revenue mark
On the operations front the company was making equally dynamic strides In 1992 it celebrated its Platinum Jubilee In 1997 the company unveiled its new corporate identity
Overveiw of the Company
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Eat Healthy Think Better - and made its first foray into the dairy products market In 1999 the Britannia Khao World Cup Jao promotion further fortified the affinity consumers had with Brand Britannia
Britannia strode into the 21st Century as one of Indias biggest brands and the pre-eminent food brand of the country It was equally recognized for its innovative approach to products and marketing the Lagaan Match was voted Indias most successful promotional activity of the year 2001 while the delicious Britannia 50-50 Maska-Chaska became Indias most successful product launch In 2002 Britannias New Business Division formed a joint venture with Fonterra the worlds second largest Dairy Company and Britannia New Zealand Foods Pvt Ltd was born In recognition of its vision and accelerating graph Forbes Global rated Britannia One amongst the Top 200 Small Companies of the World and The Economic Times pegged Britannia Indias 2nd Most Trusted Brand
Today more than a century after those tentative first steps Britannias fairy tale is not only going strong but blazing new standards and that minuscule initial investment has grown by leaps and bounds to crore of rupees in wealth for Britannias shareholders The companys offerings are spread across the spectrum with products ranging from the healthy and economical Tiger biscuits to the more lifestyle-oriented Milkman Cheese Having succeeded in garnering the trust of almost one-third of Indias one billion population and a strong management at the helm means Britannia will continue to dream big on its path of innovation and quality And millions of consumers will savor the results happily ever after
The Companys head office and registered office and work
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places are located at the below mentioned address
Registered amp Head Office
Britannia Industries Limited51A Hungerford StreetKolkata-700017
Work Places
(a) Britannia Industries Limited33 Industrial AreaLawrance RoadDelhi-110035
(b) Britannia Industries LimitedPlot No-1 Sector No-1Integrated Industrial EstatePantnagar Rudrapur-263153
(c) Britannia Industries Limited15 Taratola RoadKolkata-700088
(d) Britannia Industries LimitedMTH Road PadiChennai-600050
(e) Britannia Industries LimitedReady Road(East) MazagaonMumbai-400010
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BOARD OF DIRECTORS
Name Designation
Mr Nusli Neville Wadia Chairman
Ms Vinita Bali Managing Director
Mr AKHirjee Director
Dr Ajai Puri Director
Mr Avijit Deb Director
Mr Jeh N Wadia Director
Mr Keki Dadiseth Director
Mr Nasser Munjee Director
Mr Ness Nusli Wadia Director
Mr Nimesh N Kampani Director
Mr Pratap Khanna Director
Mr SSKelkar Director
Dr Vijay L Kelkar Director
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Management Team
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Gautam Banarjee General Manager(Materials)
A K Gupta General Manager - Accounts amp Planning
R K Agrawal Supply Chain Director for New Business Development
R S Subramaniam General Manager - Manufacturing Engineering and Projects
Anuradha Narasimhan Category Director - Health amp Wellness
Shalini Degan Category Director - Delight amp Lifestyle
T S Venketram General Manager - Manufacturing Development
Balaji Reddipalli Head Replenishment
R Anand Business Operations Director
Jehanagir Tankariwala General Manager - Human Resources
Vinod Menon Head of BNZF
Shridhar Panshikar National Sales Manager
P Govindan Company Secretary amp Head of Legal
Dr KN Shashikanth Corporate Quality Assurance Manager
V V Padnabham Corporate Manager -Information Systems
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1892 The Genesis - Britannia established with an investment of Rs 295 in Kolkata
1910 Advent of electricity sees operations mechanized 1921 Imported machinery introduced Britannia becomes
the first company East of the Suez to use gas ovens 1939 - 44 Sales rise exponentially to Rs1627202in 1939
During 1944 sales ramp up by more than eight times to reach Rs136 crore
1975 Britannia Biscuit Company takes over biscuit
distribution from Parrys
1978 Public issue - Indian shareholding crosses 60
1979 Re-christened Britannia Industries Ltd (BIL) 1983 Sales cross Rs100 crore 1989 The Executive Office relocated to Bangalore 1992 BIL celebrates its Platinum Jubilee 1993 Wadia Group acquires stake in ABIL UK and
becomes an equal partner with Groupe Danone in BIL
1994 Volumes cross 100000 tons of biscuits 1997 Re-birth - new corporate identity Eat Healthy
Think Better leads to new mission Make every
Milestones for the Company
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third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
Page 20Arpits
companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
Page 21Arpits
Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
Page 24Arpits
reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
Page 27 Arpits
Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
PREFACE
It gives an immense pleasure to present on the topic of Production of Biscuits From Short Dough By the time I completed this project I understood how important it was for a BBA student to do summer training in between the BBA program
I have selected this topic because I was very keen to know about the know how of production system A distinct feature about this project is that it provides a penetrating and comprehensive analysis of all the aspects of production concept and how it defers from bookish knowledge in a simple and lucid style
A project is involving a lot of extensive study and research it also gave me a great deal of exposure to the production department of an industry I hope this project would prove useful to its readers if it deserves
Page 03Arpits
Arpit s
STUDENTS DECLARATION
I Arpit Nagar student of BBA V sem declare that this project report PRODUCTION OF BISCUITS FROM SHORT DOUGH is written and submitted by me under the guidance of Mr Anil Anand (Production Manager Britannia Industries LtdPantnagar) is my original work The entire analysis and conclusion of this report are based on the information which is collected by me during the summer training period
The empirical findings in the report are based on the data collected by myself while preparing this project I have not copied anything from any source (other than provided by the industry officials and website) or any other project submitted for similar purpose
ARPIT NAGARBBA (2008-11)
Page 04
CONTENT SHEET
Page 05Arpits
S No
Title Page
Acknowledgment
Preface
Students Declaration
Content Sheet
Chapter - 111 Introduction about the project12 Period Of Study13 Company Overview and its Code of
Conduct14 Various Products of Britannia Industries
Ltd
Chapter-221 History of Biscuits22 Production23 Mixing24 Forming25 Baking26 Cooling27 Packaging
Questionnaire (Internal amp External) amp Findings
Bibliography
Copy of the certificate provided by the Britannia Industries Ltd
1
2
3
4
5
6
7
8
9
10
Name of Topic Page No
1
2
3
4
5
6-5167
8-23
24-51
52-8152-5455-7273-7475-7677-78
7980-81
82-92
93
94
As a part of the curriculum of my BBA V semester I undergo a project in Britannia Industries Ltd There I was assigned the project title Production Of Biscuits From Short Dough My topic is concerned with the production system of Britannia Industries through which we can check the various aspects of the production system like the procedure quality measures taken by the company etc
This project work provides me an ample opportunity to judge the companys productivity condition and performance of the workers Through productivity we can evaluate the companys performance in the comparison of other companies accomplishing the same task
Introduction
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stThe period of the study consists of two months from 1 stJuly 2010 to 31 August 2010 in a reputed industrial
organization which is one of the major industries in FMCG sector at Rudrapur-Pantnagar Zone
Address of the company
BRITANNIA INDUSTRIES LIMITEDPLOT N01 SECTOR NO1INTEGRATED INDUSTRIAL ESTATEPANTNAGAR RUDRAPUR-263153Distt UDHAM SINGH NAGARUTTARAKHAND
WEBSITE- wwwbritanniacoin
PeriodOf The Study
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The story of one of Indias favorite brands reads almost like a fairy tale Once upon a time in 1892 to be precise a biscuit company was started in a nondescript house in Calcutta (now Kolkata) with an initial investment of Rs 295 The company we all know as Britannia today
The beginnings might have been humble-the dreams were anything but By 1910 with the advent of electricity Britannia mechanized its operations and in 1921 it became the first company east of the Suez Canal to use imported gas ovens Britannias 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
As time moved on the biscuit market continued to growhellip and Britannia grew along with it In 1975 the Britannia Biscuit Company took over the distribution of biscuits from Parrys who till now distributed Britannia biscuits in India In the subsequent public issue of 1978 Indian shareholding crossed 60 firmly establishing the Indians of the firm The following year Britannia Biscuit Company was re-christened Britannia Industries Limited (BIL) Four years later in 1983 it crossed the Rs 100 crore revenue mark
On the operations front the company was making equally dynamic strides In 1992 it celebrated its Platinum Jubilee In 1997 the company unveiled its new corporate identity
Overveiw of the Company
Page 08Arpits
Eat Healthy Think Better - and made its first foray into the dairy products market In 1999 the Britannia Khao World Cup Jao promotion further fortified the affinity consumers had with Brand Britannia
Britannia strode into the 21st Century as one of Indias biggest brands and the pre-eminent food brand of the country It was equally recognized for its innovative approach to products and marketing the Lagaan Match was voted Indias most successful promotional activity of the year 2001 while the delicious Britannia 50-50 Maska-Chaska became Indias most successful product launch In 2002 Britannias New Business Division formed a joint venture with Fonterra the worlds second largest Dairy Company and Britannia New Zealand Foods Pvt Ltd was born In recognition of its vision and accelerating graph Forbes Global rated Britannia One amongst the Top 200 Small Companies of the World and The Economic Times pegged Britannia Indias 2nd Most Trusted Brand
Today more than a century after those tentative first steps Britannias fairy tale is not only going strong but blazing new standards and that minuscule initial investment has grown by leaps and bounds to crore of rupees in wealth for Britannias shareholders The companys offerings are spread across the spectrum with products ranging from the healthy and economical Tiger biscuits to the more lifestyle-oriented Milkman Cheese Having succeeded in garnering the trust of almost one-third of Indias one billion population and a strong management at the helm means Britannia will continue to dream big on its path of innovation and quality And millions of consumers will savor the results happily ever after
The Companys head office and registered office and work
Page 09Arpits
places are located at the below mentioned address
Registered amp Head Office
Britannia Industries Limited51A Hungerford StreetKolkata-700017
Work Places
(a) Britannia Industries Limited33 Industrial AreaLawrance RoadDelhi-110035
(b) Britannia Industries LimitedPlot No-1 Sector No-1Integrated Industrial EstatePantnagar Rudrapur-263153
(c) Britannia Industries Limited15 Taratola RoadKolkata-700088
(d) Britannia Industries LimitedMTH Road PadiChennai-600050
(e) Britannia Industries LimitedReady Road(East) MazagaonMumbai-400010
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BOARD OF DIRECTORS
Name Designation
Mr Nusli Neville Wadia Chairman
Ms Vinita Bali Managing Director
Mr AKHirjee Director
Dr Ajai Puri Director
Mr Avijit Deb Director
Mr Jeh N Wadia Director
Mr Keki Dadiseth Director
Mr Nasser Munjee Director
Mr Ness Nusli Wadia Director
Mr Nimesh N Kampani Director
Mr Pratap Khanna Director
Mr SSKelkar Director
Dr Vijay L Kelkar Director
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Management Team
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Gautam Banarjee General Manager(Materials)
A K Gupta General Manager - Accounts amp Planning
R K Agrawal Supply Chain Director for New Business Development
R S Subramaniam General Manager - Manufacturing Engineering and Projects
Anuradha Narasimhan Category Director - Health amp Wellness
Shalini Degan Category Director - Delight amp Lifestyle
T S Venketram General Manager - Manufacturing Development
Balaji Reddipalli Head Replenishment
R Anand Business Operations Director
Jehanagir Tankariwala General Manager - Human Resources
Vinod Menon Head of BNZF
Shridhar Panshikar National Sales Manager
P Govindan Company Secretary amp Head of Legal
Dr KN Shashikanth Corporate Quality Assurance Manager
V V Padnabham Corporate Manager -Information Systems
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1892 The Genesis - Britannia established with an investment of Rs 295 in Kolkata
1910 Advent of electricity sees operations mechanized 1921 Imported machinery introduced Britannia becomes
the first company East of the Suez to use gas ovens 1939 - 44 Sales rise exponentially to Rs1627202in 1939
During 1944 sales ramp up by more than eight times to reach Rs136 crore
1975 Britannia Biscuit Company takes over biscuit
distribution from Parrys
1978 Public issue - Indian shareholding crosses 60
1979 Re-christened Britannia Industries Ltd (BIL) 1983 Sales cross Rs100 crore 1989 The Executive Office relocated to Bangalore 1992 BIL celebrates its Platinum Jubilee 1993 Wadia Group acquires stake in ABIL UK and
becomes an equal partner with Groupe Danone in BIL
1994 Volumes cross 100000 tons of biscuits 1997 Re-birth - new corporate identity Eat Healthy
Think Better leads to new mission Make every
Milestones for the Company
Page 14Arpits
third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
Page 16Arpits
Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
Page 17Arpits
The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
Page 18Arpits
3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
Page 19Arpits
ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
Page 20Arpits
companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Arpit s
STUDENTS DECLARATION
I Arpit Nagar student of BBA V sem declare that this project report PRODUCTION OF BISCUITS FROM SHORT DOUGH is written and submitted by me under the guidance of Mr Anil Anand (Production Manager Britannia Industries LtdPantnagar) is my original work The entire analysis and conclusion of this report are based on the information which is collected by me during the summer training period
The empirical findings in the report are based on the data collected by myself while preparing this project I have not copied anything from any source (other than provided by the industry officials and website) or any other project submitted for similar purpose
ARPIT NAGARBBA (2008-11)
Page 04
CONTENT SHEET
Page 05Arpits
S No
Title Page
Acknowledgment
Preface
Students Declaration
Content Sheet
Chapter - 111 Introduction about the project12 Period Of Study13 Company Overview and its Code of
Conduct14 Various Products of Britannia Industries
Ltd
Chapter-221 History of Biscuits22 Production23 Mixing24 Forming25 Baking26 Cooling27 Packaging
Questionnaire (Internal amp External) amp Findings
Bibliography
Copy of the certificate provided by the Britannia Industries Ltd
1
2
3
4
5
6
7
8
9
10
Name of Topic Page No
1
2
3
4
5
6-5167
8-23
24-51
52-8152-5455-7273-7475-7677-78
7980-81
82-92
93
94
As a part of the curriculum of my BBA V semester I undergo a project in Britannia Industries Ltd There I was assigned the project title Production Of Biscuits From Short Dough My topic is concerned with the production system of Britannia Industries through which we can check the various aspects of the production system like the procedure quality measures taken by the company etc
This project work provides me an ample opportunity to judge the companys productivity condition and performance of the workers Through productivity we can evaluate the companys performance in the comparison of other companies accomplishing the same task
Introduction
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stThe period of the study consists of two months from 1 stJuly 2010 to 31 August 2010 in a reputed industrial
organization which is one of the major industries in FMCG sector at Rudrapur-Pantnagar Zone
Address of the company
BRITANNIA INDUSTRIES LIMITEDPLOT N01 SECTOR NO1INTEGRATED INDUSTRIAL ESTATEPANTNAGAR RUDRAPUR-263153Distt UDHAM SINGH NAGARUTTARAKHAND
WEBSITE- wwwbritanniacoin
PeriodOf The Study
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The story of one of Indias favorite brands reads almost like a fairy tale Once upon a time in 1892 to be precise a biscuit company was started in a nondescript house in Calcutta (now Kolkata) with an initial investment of Rs 295 The company we all know as Britannia today
The beginnings might have been humble-the dreams were anything but By 1910 with the advent of electricity Britannia mechanized its operations and in 1921 it became the first company east of the Suez Canal to use imported gas ovens Britannias 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
As time moved on the biscuit market continued to growhellip and Britannia grew along with it In 1975 the Britannia Biscuit Company took over the distribution of biscuits from Parrys who till now distributed Britannia biscuits in India In the subsequent public issue of 1978 Indian shareholding crossed 60 firmly establishing the Indians of the firm The following year Britannia Biscuit Company was re-christened Britannia Industries Limited (BIL) Four years later in 1983 it crossed the Rs 100 crore revenue mark
On the operations front the company was making equally dynamic strides In 1992 it celebrated its Platinum Jubilee In 1997 the company unveiled its new corporate identity
Overveiw of the Company
Page 08Arpits
Eat Healthy Think Better - and made its first foray into the dairy products market In 1999 the Britannia Khao World Cup Jao promotion further fortified the affinity consumers had with Brand Britannia
Britannia strode into the 21st Century as one of Indias biggest brands and the pre-eminent food brand of the country It was equally recognized for its innovative approach to products and marketing the Lagaan Match was voted Indias most successful promotional activity of the year 2001 while the delicious Britannia 50-50 Maska-Chaska became Indias most successful product launch In 2002 Britannias New Business Division formed a joint venture with Fonterra the worlds second largest Dairy Company and Britannia New Zealand Foods Pvt Ltd was born In recognition of its vision and accelerating graph Forbes Global rated Britannia One amongst the Top 200 Small Companies of the World and The Economic Times pegged Britannia Indias 2nd Most Trusted Brand
Today more than a century after those tentative first steps Britannias fairy tale is not only going strong but blazing new standards and that minuscule initial investment has grown by leaps and bounds to crore of rupees in wealth for Britannias shareholders The companys offerings are spread across the spectrum with products ranging from the healthy and economical Tiger biscuits to the more lifestyle-oriented Milkman Cheese Having succeeded in garnering the trust of almost one-third of Indias one billion population and a strong management at the helm means Britannia will continue to dream big on its path of innovation and quality And millions of consumers will savor the results happily ever after
The Companys head office and registered office and work
Page 09Arpits
places are located at the below mentioned address
Registered amp Head Office
Britannia Industries Limited51A Hungerford StreetKolkata-700017
Work Places
(a) Britannia Industries Limited33 Industrial AreaLawrance RoadDelhi-110035
(b) Britannia Industries LimitedPlot No-1 Sector No-1Integrated Industrial EstatePantnagar Rudrapur-263153
(c) Britannia Industries Limited15 Taratola RoadKolkata-700088
(d) Britannia Industries LimitedMTH Road PadiChennai-600050
(e) Britannia Industries LimitedReady Road(East) MazagaonMumbai-400010
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BOARD OF DIRECTORS
Name Designation
Mr Nusli Neville Wadia Chairman
Ms Vinita Bali Managing Director
Mr AKHirjee Director
Dr Ajai Puri Director
Mr Avijit Deb Director
Mr Jeh N Wadia Director
Mr Keki Dadiseth Director
Mr Nasser Munjee Director
Mr Ness Nusli Wadia Director
Mr Nimesh N Kampani Director
Mr Pratap Khanna Director
Mr SSKelkar Director
Dr Vijay L Kelkar Director
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Management Team
Page 12Arpits
Gautam Banarjee General Manager(Materials)
A K Gupta General Manager - Accounts amp Planning
R K Agrawal Supply Chain Director for New Business Development
R S Subramaniam General Manager - Manufacturing Engineering and Projects
Anuradha Narasimhan Category Director - Health amp Wellness
Shalini Degan Category Director - Delight amp Lifestyle
T S Venketram General Manager - Manufacturing Development
Balaji Reddipalli Head Replenishment
R Anand Business Operations Director
Jehanagir Tankariwala General Manager - Human Resources
Vinod Menon Head of BNZF
Shridhar Panshikar National Sales Manager
P Govindan Company Secretary amp Head of Legal
Dr KN Shashikanth Corporate Quality Assurance Manager
V V Padnabham Corporate Manager -Information Systems
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1892 The Genesis - Britannia established with an investment of Rs 295 in Kolkata
1910 Advent of electricity sees operations mechanized 1921 Imported machinery introduced Britannia becomes
the first company East of the Suez to use gas ovens 1939 - 44 Sales rise exponentially to Rs1627202in 1939
During 1944 sales ramp up by more than eight times to reach Rs136 crore
1975 Britannia Biscuit Company takes over biscuit
distribution from Parrys
1978 Public issue - Indian shareholding crosses 60
1979 Re-christened Britannia Industries Ltd (BIL) 1983 Sales cross Rs100 crore 1989 The Executive Office relocated to Bangalore 1992 BIL celebrates its Platinum Jubilee 1993 Wadia Group acquires stake in ABIL UK and
becomes an equal partner with Groupe Danone in BIL
1994 Volumes cross 100000 tons of biscuits 1997 Re-birth - new corporate identity Eat Healthy
Think Better leads to new mission Make every
Milestones for the Company
Page 14Arpits
third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
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companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
CONTENT SHEET
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S No
Title Page
Acknowledgment
Preface
Students Declaration
Content Sheet
Chapter - 111 Introduction about the project12 Period Of Study13 Company Overview and its Code of
Conduct14 Various Products of Britannia Industries
Ltd
Chapter-221 History of Biscuits22 Production23 Mixing24 Forming25 Baking26 Cooling27 Packaging
Questionnaire (Internal amp External) amp Findings
Bibliography
Copy of the certificate provided by the Britannia Industries Ltd
1
2
3
4
5
6
7
8
9
10
Name of Topic Page No
1
2
3
4
5
6-5167
8-23
24-51
52-8152-5455-7273-7475-7677-78
7980-81
82-92
93
94
As a part of the curriculum of my BBA V semester I undergo a project in Britannia Industries Ltd There I was assigned the project title Production Of Biscuits From Short Dough My topic is concerned with the production system of Britannia Industries through which we can check the various aspects of the production system like the procedure quality measures taken by the company etc
This project work provides me an ample opportunity to judge the companys productivity condition and performance of the workers Through productivity we can evaluate the companys performance in the comparison of other companies accomplishing the same task
Introduction
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stThe period of the study consists of two months from 1 stJuly 2010 to 31 August 2010 in a reputed industrial
organization which is one of the major industries in FMCG sector at Rudrapur-Pantnagar Zone
Address of the company
BRITANNIA INDUSTRIES LIMITEDPLOT N01 SECTOR NO1INTEGRATED INDUSTRIAL ESTATEPANTNAGAR RUDRAPUR-263153Distt UDHAM SINGH NAGARUTTARAKHAND
WEBSITE- wwwbritanniacoin
PeriodOf The Study
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The story of one of Indias favorite brands reads almost like a fairy tale Once upon a time in 1892 to be precise a biscuit company was started in a nondescript house in Calcutta (now Kolkata) with an initial investment of Rs 295 The company we all know as Britannia today
The beginnings might have been humble-the dreams were anything but By 1910 with the advent of electricity Britannia mechanized its operations and in 1921 it became the first company east of the Suez Canal to use imported gas ovens Britannias 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
As time moved on the biscuit market continued to growhellip and Britannia grew along with it In 1975 the Britannia Biscuit Company took over the distribution of biscuits from Parrys who till now distributed Britannia biscuits in India In the subsequent public issue of 1978 Indian shareholding crossed 60 firmly establishing the Indians of the firm The following year Britannia Biscuit Company was re-christened Britannia Industries Limited (BIL) Four years later in 1983 it crossed the Rs 100 crore revenue mark
On the operations front the company was making equally dynamic strides In 1992 it celebrated its Platinum Jubilee In 1997 the company unveiled its new corporate identity
Overveiw of the Company
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Eat Healthy Think Better - and made its first foray into the dairy products market In 1999 the Britannia Khao World Cup Jao promotion further fortified the affinity consumers had with Brand Britannia
Britannia strode into the 21st Century as one of Indias biggest brands and the pre-eminent food brand of the country It was equally recognized for its innovative approach to products and marketing the Lagaan Match was voted Indias most successful promotional activity of the year 2001 while the delicious Britannia 50-50 Maska-Chaska became Indias most successful product launch In 2002 Britannias New Business Division formed a joint venture with Fonterra the worlds second largest Dairy Company and Britannia New Zealand Foods Pvt Ltd was born In recognition of its vision and accelerating graph Forbes Global rated Britannia One amongst the Top 200 Small Companies of the World and The Economic Times pegged Britannia Indias 2nd Most Trusted Brand
Today more than a century after those tentative first steps Britannias fairy tale is not only going strong but blazing new standards and that minuscule initial investment has grown by leaps and bounds to crore of rupees in wealth for Britannias shareholders The companys offerings are spread across the spectrum with products ranging from the healthy and economical Tiger biscuits to the more lifestyle-oriented Milkman Cheese Having succeeded in garnering the trust of almost one-third of Indias one billion population and a strong management at the helm means Britannia will continue to dream big on its path of innovation and quality And millions of consumers will savor the results happily ever after
The Companys head office and registered office and work
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places are located at the below mentioned address
Registered amp Head Office
Britannia Industries Limited51A Hungerford StreetKolkata-700017
Work Places
(a) Britannia Industries Limited33 Industrial AreaLawrance RoadDelhi-110035
(b) Britannia Industries LimitedPlot No-1 Sector No-1Integrated Industrial EstatePantnagar Rudrapur-263153
(c) Britannia Industries Limited15 Taratola RoadKolkata-700088
(d) Britannia Industries LimitedMTH Road PadiChennai-600050
(e) Britannia Industries LimitedReady Road(East) MazagaonMumbai-400010
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BOARD OF DIRECTORS
Name Designation
Mr Nusli Neville Wadia Chairman
Ms Vinita Bali Managing Director
Mr AKHirjee Director
Dr Ajai Puri Director
Mr Avijit Deb Director
Mr Jeh N Wadia Director
Mr Keki Dadiseth Director
Mr Nasser Munjee Director
Mr Ness Nusli Wadia Director
Mr Nimesh N Kampani Director
Mr Pratap Khanna Director
Mr SSKelkar Director
Dr Vijay L Kelkar Director
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Management Team
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Gautam Banarjee General Manager(Materials)
A K Gupta General Manager - Accounts amp Planning
R K Agrawal Supply Chain Director for New Business Development
R S Subramaniam General Manager - Manufacturing Engineering and Projects
Anuradha Narasimhan Category Director - Health amp Wellness
Shalini Degan Category Director - Delight amp Lifestyle
T S Venketram General Manager - Manufacturing Development
Balaji Reddipalli Head Replenishment
R Anand Business Operations Director
Jehanagir Tankariwala General Manager - Human Resources
Vinod Menon Head of BNZF
Shridhar Panshikar National Sales Manager
P Govindan Company Secretary amp Head of Legal
Dr KN Shashikanth Corporate Quality Assurance Manager
V V Padnabham Corporate Manager -Information Systems
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1892 The Genesis - Britannia established with an investment of Rs 295 in Kolkata
1910 Advent of electricity sees operations mechanized 1921 Imported machinery introduced Britannia becomes
the first company East of the Suez to use gas ovens 1939 - 44 Sales rise exponentially to Rs1627202in 1939
During 1944 sales ramp up by more than eight times to reach Rs136 crore
1975 Britannia Biscuit Company takes over biscuit
distribution from Parrys
1978 Public issue - Indian shareholding crosses 60
1979 Re-christened Britannia Industries Ltd (BIL) 1983 Sales cross Rs100 crore 1989 The Executive Office relocated to Bangalore 1992 BIL celebrates its Platinum Jubilee 1993 Wadia Group acquires stake in ABIL UK and
becomes an equal partner with Groupe Danone in BIL
1994 Volumes cross 100000 tons of biscuits 1997 Re-birth - new corporate identity Eat Healthy
Think Better leads to new mission Make every
Milestones for the Company
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third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
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companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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As a part of the curriculum of my BBA V semester I undergo a project in Britannia Industries Ltd There I was assigned the project title Production Of Biscuits From Short Dough My topic is concerned with the production system of Britannia Industries through which we can check the various aspects of the production system like the procedure quality measures taken by the company etc
This project work provides me an ample opportunity to judge the companys productivity condition and performance of the workers Through productivity we can evaluate the companys performance in the comparison of other companies accomplishing the same task
Introduction
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stThe period of the study consists of two months from 1 stJuly 2010 to 31 August 2010 in a reputed industrial
organization which is one of the major industries in FMCG sector at Rudrapur-Pantnagar Zone
Address of the company
BRITANNIA INDUSTRIES LIMITEDPLOT N01 SECTOR NO1INTEGRATED INDUSTRIAL ESTATEPANTNAGAR RUDRAPUR-263153Distt UDHAM SINGH NAGARUTTARAKHAND
WEBSITE- wwwbritanniacoin
PeriodOf The Study
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The story of one of Indias favorite brands reads almost like a fairy tale Once upon a time in 1892 to be precise a biscuit company was started in a nondescript house in Calcutta (now Kolkata) with an initial investment of Rs 295 The company we all know as Britannia today
The beginnings might have been humble-the dreams were anything but By 1910 with the advent of electricity Britannia mechanized its operations and in 1921 it became the first company east of the Suez Canal to use imported gas ovens Britannias 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
As time moved on the biscuit market continued to growhellip and Britannia grew along with it In 1975 the Britannia Biscuit Company took over the distribution of biscuits from Parrys who till now distributed Britannia biscuits in India In the subsequent public issue of 1978 Indian shareholding crossed 60 firmly establishing the Indians of the firm The following year Britannia Biscuit Company was re-christened Britannia Industries Limited (BIL) Four years later in 1983 it crossed the Rs 100 crore revenue mark
On the operations front the company was making equally dynamic strides In 1992 it celebrated its Platinum Jubilee In 1997 the company unveiled its new corporate identity
Overveiw of the Company
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Eat Healthy Think Better - and made its first foray into the dairy products market In 1999 the Britannia Khao World Cup Jao promotion further fortified the affinity consumers had with Brand Britannia
Britannia strode into the 21st Century as one of Indias biggest brands and the pre-eminent food brand of the country It was equally recognized for its innovative approach to products and marketing the Lagaan Match was voted Indias most successful promotional activity of the year 2001 while the delicious Britannia 50-50 Maska-Chaska became Indias most successful product launch In 2002 Britannias New Business Division formed a joint venture with Fonterra the worlds second largest Dairy Company and Britannia New Zealand Foods Pvt Ltd was born In recognition of its vision and accelerating graph Forbes Global rated Britannia One amongst the Top 200 Small Companies of the World and The Economic Times pegged Britannia Indias 2nd Most Trusted Brand
Today more than a century after those tentative first steps Britannias fairy tale is not only going strong but blazing new standards and that minuscule initial investment has grown by leaps and bounds to crore of rupees in wealth for Britannias shareholders The companys offerings are spread across the spectrum with products ranging from the healthy and economical Tiger biscuits to the more lifestyle-oriented Milkman Cheese Having succeeded in garnering the trust of almost one-third of Indias one billion population and a strong management at the helm means Britannia will continue to dream big on its path of innovation and quality And millions of consumers will savor the results happily ever after
The Companys head office and registered office and work
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places are located at the below mentioned address
Registered amp Head Office
Britannia Industries Limited51A Hungerford StreetKolkata-700017
Work Places
(a) Britannia Industries Limited33 Industrial AreaLawrance RoadDelhi-110035
(b) Britannia Industries LimitedPlot No-1 Sector No-1Integrated Industrial EstatePantnagar Rudrapur-263153
(c) Britannia Industries Limited15 Taratola RoadKolkata-700088
(d) Britannia Industries LimitedMTH Road PadiChennai-600050
(e) Britannia Industries LimitedReady Road(East) MazagaonMumbai-400010
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BOARD OF DIRECTORS
Name Designation
Mr Nusli Neville Wadia Chairman
Ms Vinita Bali Managing Director
Mr AKHirjee Director
Dr Ajai Puri Director
Mr Avijit Deb Director
Mr Jeh N Wadia Director
Mr Keki Dadiseth Director
Mr Nasser Munjee Director
Mr Ness Nusli Wadia Director
Mr Nimesh N Kampani Director
Mr Pratap Khanna Director
Mr SSKelkar Director
Dr Vijay L Kelkar Director
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Management Team
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Gautam Banarjee General Manager(Materials)
A K Gupta General Manager - Accounts amp Planning
R K Agrawal Supply Chain Director for New Business Development
R S Subramaniam General Manager - Manufacturing Engineering and Projects
Anuradha Narasimhan Category Director - Health amp Wellness
Shalini Degan Category Director - Delight amp Lifestyle
T S Venketram General Manager - Manufacturing Development
Balaji Reddipalli Head Replenishment
R Anand Business Operations Director
Jehanagir Tankariwala General Manager - Human Resources
Vinod Menon Head of BNZF
Shridhar Panshikar National Sales Manager
P Govindan Company Secretary amp Head of Legal
Dr KN Shashikanth Corporate Quality Assurance Manager
V V Padnabham Corporate Manager -Information Systems
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1892 The Genesis - Britannia established with an investment of Rs 295 in Kolkata
1910 Advent of electricity sees operations mechanized 1921 Imported machinery introduced Britannia becomes
the first company East of the Suez to use gas ovens 1939 - 44 Sales rise exponentially to Rs1627202in 1939
During 1944 sales ramp up by more than eight times to reach Rs136 crore
1975 Britannia Biscuit Company takes over biscuit
distribution from Parrys
1978 Public issue - Indian shareholding crosses 60
1979 Re-christened Britannia Industries Ltd (BIL) 1983 Sales cross Rs100 crore 1989 The Executive Office relocated to Bangalore 1992 BIL celebrates its Platinum Jubilee 1993 Wadia Group acquires stake in ABIL UK and
becomes an equal partner with Groupe Danone in BIL
1994 Volumes cross 100000 tons of biscuits 1997 Re-birth - new corporate identity Eat Healthy
Think Better leads to new mission Make every
Milestones for the Company
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third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
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companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
stThe period of the study consists of two months from 1 stJuly 2010 to 31 August 2010 in a reputed industrial
organization which is one of the major industries in FMCG sector at Rudrapur-Pantnagar Zone
Address of the company
BRITANNIA INDUSTRIES LIMITEDPLOT N01 SECTOR NO1INTEGRATED INDUSTRIAL ESTATEPANTNAGAR RUDRAPUR-263153Distt UDHAM SINGH NAGARUTTARAKHAND
WEBSITE- wwwbritanniacoin
PeriodOf The Study
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The story of one of Indias favorite brands reads almost like a fairy tale Once upon a time in 1892 to be precise a biscuit company was started in a nondescript house in Calcutta (now Kolkata) with an initial investment of Rs 295 The company we all know as Britannia today
The beginnings might have been humble-the dreams were anything but By 1910 with the advent of electricity Britannia mechanized its operations and in 1921 it became the first company east of the Suez Canal to use imported gas ovens Britannias 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
As time moved on the biscuit market continued to growhellip and Britannia grew along with it In 1975 the Britannia Biscuit Company took over the distribution of biscuits from Parrys who till now distributed Britannia biscuits in India In the subsequent public issue of 1978 Indian shareholding crossed 60 firmly establishing the Indians of the firm The following year Britannia Biscuit Company was re-christened Britannia Industries Limited (BIL) Four years later in 1983 it crossed the Rs 100 crore revenue mark
On the operations front the company was making equally dynamic strides In 1992 it celebrated its Platinum Jubilee In 1997 the company unveiled its new corporate identity
Overveiw of the Company
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Eat Healthy Think Better - and made its first foray into the dairy products market In 1999 the Britannia Khao World Cup Jao promotion further fortified the affinity consumers had with Brand Britannia
Britannia strode into the 21st Century as one of Indias biggest brands and the pre-eminent food brand of the country It was equally recognized for its innovative approach to products and marketing the Lagaan Match was voted Indias most successful promotional activity of the year 2001 while the delicious Britannia 50-50 Maska-Chaska became Indias most successful product launch In 2002 Britannias New Business Division formed a joint venture with Fonterra the worlds second largest Dairy Company and Britannia New Zealand Foods Pvt Ltd was born In recognition of its vision and accelerating graph Forbes Global rated Britannia One amongst the Top 200 Small Companies of the World and The Economic Times pegged Britannia Indias 2nd Most Trusted Brand
Today more than a century after those tentative first steps Britannias fairy tale is not only going strong but blazing new standards and that minuscule initial investment has grown by leaps and bounds to crore of rupees in wealth for Britannias shareholders The companys offerings are spread across the spectrum with products ranging from the healthy and economical Tiger biscuits to the more lifestyle-oriented Milkman Cheese Having succeeded in garnering the trust of almost one-third of Indias one billion population and a strong management at the helm means Britannia will continue to dream big on its path of innovation and quality And millions of consumers will savor the results happily ever after
The Companys head office and registered office and work
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places are located at the below mentioned address
Registered amp Head Office
Britannia Industries Limited51A Hungerford StreetKolkata-700017
Work Places
(a) Britannia Industries Limited33 Industrial AreaLawrance RoadDelhi-110035
(b) Britannia Industries LimitedPlot No-1 Sector No-1Integrated Industrial EstatePantnagar Rudrapur-263153
(c) Britannia Industries Limited15 Taratola RoadKolkata-700088
(d) Britannia Industries LimitedMTH Road PadiChennai-600050
(e) Britannia Industries LimitedReady Road(East) MazagaonMumbai-400010
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BOARD OF DIRECTORS
Name Designation
Mr Nusli Neville Wadia Chairman
Ms Vinita Bali Managing Director
Mr AKHirjee Director
Dr Ajai Puri Director
Mr Avijit Deb Director
Mr Jeh N Wadia Director
Mr Keki Dadiseth Director
Mr Nasser Munjee Director
Mr Ness Nusli Wadia Director
Mr Nimesh N Kampani Director
Mr Pratap Khanna Director
Mr SSKelkar Director
Dr Vijay L Kelkar Director
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Management Team
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Gautam Banarjee General Manager(Materials)
A K Gupta General Manager - Accounts amp Planning
R K Agrawal Supply Chain Director for New Business Development
R S Subramaniam General Manager - Manufacturing Engineering and Projects
Anuradha Narasimhan Category Director - Health amp Wellness
Shalini Degan Category Director - Delight amp Lifestyle
T S Venketram General Manager - Manufacturing Development
Balaji Reddipalli Head Replenishment
R Anand Business Operations Director
Jehanagir Tankariwala General Manager - Human Resources
Vinod Menon Head of BNZF
Shridhar Panshikar National Sales Manager
P Govindan Company Secretary amp Head of Legal
Dr KN Shashikanth Corporate Quality Assurance Manager
V V Padnabham Corporate Manager -Information Systems
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1892 The Genesis - Britannia established with an investment of Rs 295 in Kolkata
1910 Advent of electricity sees operations mechanized 1921 Imported machinery introduced Britannia becomes
the first company East of the Suez to use gas ovens 1939 - 44 Sales rise exponentially to Rs1627202in 1939
During 1944 sales ramp up by more than eight times to reach Rs136 crore
1975 Britannia Biscuit Company takes over biscuit
distribution from Parrys
1978 Public issue - Indian shareholding crosses 60
1979 Re-christened Britannia Industries Ltd (BIL) 1983 Sales cross Rs100 crore 1989 The Executive Office relocated to Bangalore 1992 BIL celebrates its Platinum Jubilee 1993 Wadia Group acquires stake in ABIL UK and
becomes an equal partner with Groupe Danone in BIL
1994 Volumes cross 100000 tons of biscuits 1997 Re-birth - new corporate identity Eat Healthy
Think Better leads to new mission Make every
Milestones for the Company
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third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
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companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
The story of one of Indias favorite brands reads almost like a fairy tale Once upon a time in 1892 to be precise a biscuit company was started in a nondescript house in Calcutta (now Kolkata) with an initial investment of Rs 295 The company we all know as Britannia today
The beginnings might have been humble-the dreams were anything but By 1910 with the advent of electricity Britannia mechanized its operations and in 1921 it became the first company east of the Suez Canal to use imported gas ovens Britannias 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
As time moved on the biscuit market continued to growhellip and Britannia grew along with it In 1975 the Britannia Biscuit Company took over the distribution of biscuits from Parrys who till now distributed Britannia biscuits in India In the subsequent public issue of 1978 Indian shareholding crossed 60 firmly establishing the Indians of the firm The following year Britannia Biscuit Company was re-christened Britannia Industries Limited (BIL) Four years later in 1983 it crossed the Rs 100 crore revenue mark
On the operations front the company was making equally dynamic strides In 1992 it celebrated its Platinum Jubilee In 1997 the company unveiled its new corporate identity
Overveiw of the Company
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Eat Healthy Think Better - and made its first foray into the dairy products market In 1999 the Britannia Khao World Cup Jao promotion further fortified the affinity consumers had with Brand Britannia
Britannia strode into the 21st Century as one of Indias biggest brands and the pre-eminent food brand of the country It was equally recognized for its innovative approach to products and marketing the Lagaan Match was voted Indias most successful promotional activity of the year 2001 while the delicious Britannia 50-50 Maska-Chaska became Indias most successful product launch In 2002 Britannias New Business Division formed a joint venture with Fonterra the worlds second largest Dairy Company and Britannia New Zealand Foods Pvt Ltd was born In recognition of its vision and accelerating graph Forbes Global rated Britannia One amongst the Top 200 Small Companies of the World and The Economic Times pegged Britannia Indias 2nd Most Trusted Brand
Today more than a century after those tentative first steps Britannias fairy tale is not only going strong but blazing new standards and that minuscule initial investment has grown by leaps and bounds to crore of rupees in wealth for Britannias shareholders The companys offerings are spread across the spectrum with products ranging from the healthy and economical Tiger biscuits to the more lifestyle-oriented Milkman Cheese Having succeeded in garnering the trust of almost one-third of Indias one billion population and a strong management at the helm means Britannia will continue to dream big on its path of innovation and quality And millions of consumers will savor the results happily ever after
The Companys head office and registered office and work
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places are located at the below mentioned address
Registered amp Head Office
Britannia Industries Limited51A Hungerford StreetKolkata-700017
Work Places
(a) Britannia Industries Limited33 Industrial AreaLawrance RoadDelhi-110035
(b) Britannia Industries LimitedPlot No-1 Sector No-1Integrated Industrial EstatePantnagar Rudrapur-263153
(c) Britannia Industries Limited15 Taratola RoadKolkata-700088
(d) Britannia Industries LimitedMTH Road PadiChennai-600050
(e) Britannia Industries LimitedReady Road(East) MazagaonMumbai-400010
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BOARD OF DIRECTORS
Name Designation
Mr Nusli Neville Wadia Chairman
Ms Vinita Bali Managing Director
Mr AKHirjee Director
Dr Ajai Puri Director
Mr Avijit Deb Director
Mr Jeh N Wadia Director
Mr Keki Dadiseth Director
Mr Nasser Munjee Director
Mr Ness Nusli Wadia Director
Mr Nimesh N Kampani Director
Mr Pratap Khanna Director
Mr SSKelkar Director
Dr Vijay L Kelkar Director
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Management Team
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Gautam Banarjee General Manager(Materials)
A K Gupta General Manager - Accounts amp Planning
R K Agrawal Supply Chain Director for New Business Development
R S Subramaniam General Manager - Manufacturing Engineering and Projects
Anuradha Narasimhan Category Director - Health amp Wellness
Shalini Degan Category Director - Delight amp Lifestyle
T S Venketram General Manager - Manufacturing Development
Balaji Reddipalli Head Replenishment
R Anand Business Operations Director
Jehanagir Tankariwala General Manager - Human Resources
Vinod Menon Head of BNZF
Shridhar Panshikar National Sales Manager
P Govindan Company Secretary amp Head of Legal
Dr KN Shashikanth Corporate Quality Assurance Manager
V V Padnabham Corporate Manager -Information Systems
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1892 The Genesis - Britannia established with an investment of Rs 295 in Kolkata
1910 Advent of electricity sees operations mechanized 1921 Imported machinery introduced Britannia becomes
the first company East of the Suez to use gas ovens 1939 - 44 Sales rise exponentially to Rs1627202in 1939
During 1944 sales ramp up by more than eight times to reach Rs136 crore
1975 Britannia Biscuit Company takes over biscuit
distribution from Parrys
1978 Public issue - Indian shareholding crosses 60
1979 Re-christened Britannia Industries Ltd (BIL) 1983 Sales cross Rs100 crore 1989 The Executive Office relocated to Bangalore 1992 BIL celebrates its Platinum Jubilee 1993 Wadia Group acquires stake in ABIL UK and
becomes an equal partner with Groupe Danone in BIL
1994 Volumes cross 100000 tons of biscuits 1997 Re-birth - new corporate identity Eat Healthy
Think Better leads to new mission Make every
Milestones for the Company
Page 14Arpits
third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
Page 20Arpits
companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
Page 21Arpits
Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Eat Healthy Think Better - and made its first foray into the dairy products market In 1999 the Britannia Khao World Cup Jao promotion further fortified the affinity consumers had with Brand Britannia
Britannia strode into the 21st Century as one of Indias biggest brands and the pre-eminent food brand of the country It was equally recognized for its innovative approach to products and marketing the Lagaan Match was voted Indias most successful promotional activity of the year 2001 while the delicious Britannia 50-50 Maska-Chaska became Indias most successful product launch In 2002 Britannias New Business Division formed a joint venture with Fonterra the worlds second largest Dairy Company and Britannia New Zealand Foods Pvt Ltd was born In recognition of its vision and accelerating graph Forbes Global rated Britannia One amongst the Top 200 Small Companies of the World and The Economic Times pegged Britannia Indias 2nd Most Trusted Brand
Today more than a century after those tentative first steps Britannias fairy tale is not only going strong but blazing new standards and that minuscule initial investment has grown by leaps and bounds to crore of rupees in wealth for Britannias shareholders The companys offerings are spread across the spectrum with products ranging from the healthy and economical Tiger biscuits to the more lifestyle-oriented Milkman Cheese Having succeeded in garnering the trust of almost one-third of Indias one billion population and a strong management at the helm means Britannia will continue to dream big on its path of innovation and quality And millions of consumers will savor the results happily ever after
The Companys head office and registered office and work
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places are located at the below mentioned address
Registered amp Head Office
Britannia Industries Limited51A Hungerford StreetKolkata-700017
Work Places
(a) Britannia Industries Limited33 Industrial AreaLawrance RoadDelhi-110035
(b) Britannia Industries LimitedPlot No-1 Sector No-1Integrated Industrial EstatePantnagar Rudrapur-263153
(c) Britannia Industries Limited15 Taratola RoadKolkata-700088
(d) Britannia Industries LimitedMTH Road PadiChennai-600050
(e) Britannia Industries LimitedReady Road(East) MazagaonMumbai-400010
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BOARD OF DIRECTORS
Name Designation
Mr Nusli Neville Wadia Chairman
Ms Vinita Bali Managing Director
Mr AKHirjee Director
Dr Ajai Puri Director
Mr Avijit Deb Director
Mr Jeh N Wadia Director
Mr Keki Dadiseth Director
Mr Nasser Munjee Director
Mr Ness Nusli Wadia Director
Mr Nimesh N Kampani Director
Mr Pratap Khanna Director
Mr SSKelkar Director
Dr Vijay L Kelkar Director
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Management Team
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Gautam Banarjee General Manager(Materials)
A K Gupta General Manager - Accounts amp Planning
R K Agrawal Supply Chain Director for New Business Development
R S Subramaniam General Manager - Manufacturing Engineering and Projects
Anuradha Narasimhan Category Director - Health amp Wellness
Shalini Degan Category Director - Delight amp Lifestyle
T S Venketram General Manager - Manufacturing Development
Balaji Reddipalli Head Replenishment
R Anand Business Operations Director
Jehanagir Tankariwala General Manager - Human Resources
Vinod Menon Head of BNZF
Shridhar Panshikar National Sales Manager
P Govindan Company Secretary amp Head of Legal
Dr KN Shashikanth Corporate Quality Assurance Manager
V V Padnabham Corporate Manager -Information Systems
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1892 The Genesis - Britannia established with an investment of Rs 295 in Kolkata
1910 Advent of electricity sees operations mechanized 1921 Imported machinery introduced Britannia becomes
the first company East of the Suez to use gas ovens 1939 - 44 Sales rise exponentially to Rs1627202in 1939
During 1944 sales ramp up by more than eight times to reach Rs136 crore
1975 Britannia Biscuit Company takes over biscuit
distribution from Parrys
1978 Public issue - Indian shareholding crosses 60
1979 Re-christened Britannia Industries Ltd (BIL) 1983 Sales cross Rs100 crore 1989 The Executive Office relocated to Bangalore 1992 BIL celebrates its Platinum Jubilee 1993 Wadia Group acquires stake in ABIL UK and
becomes an equal partner with Groupe Danone in BIL
1994 Volumes cross 100000 tons of biscuits 1997 Re-birth - new corporate identity Eat Healthy
Think Better leads to new mission Make every
Milestones for the Company
Page 14Arpits
third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
Page 19Arpits
ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
Page 20Arpits
companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
Page 21Arpits
Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
places are located at the below mentioned address
Registered amp Head Office
Britannia Industries Limited51A Hungerford StreetKolkata-700017
Work Places
(a) Britannia Industries Limited33 Industrial AreaLawrance RoadDelhi-110035
(b) Britannia Industries LimitedPlot No-1 Sector No-1Integrated Industrial EstatePantnagar Rudrapur-263153
(c) Britannia Industries Limited15 Taratola RoadKolkata-700088
(d) Britannia Industries LimitedMTH Road PadiChennai-600050
(e) Britannia Industries LimitedReady Road(East) MazagaonMumbai-400010
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BOARD OF DIRECTORS
Name Designation
Mr Nusli Neville Wadia Chairman
Ms Vinita Bali Managing Director
Mr AKHirjee Director
Dr Ajai Puri Director
Mr Avijit Deb Director
Mr Jeh N Wadia Director
Mr Keki Dadiseth Director
Mr Nasser Munjee Director
Mr Ness Nusli Wadia Director
Mr Nimesh N Kampani Director
Mr Pratap Khanna Director
Mr SSKelkar Director
Dr Vijay L Kelkar Director
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Management Team
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Gautam Banarjee General Manager(Materials)
A K Gupta General Manager - Accounts amp Planning
R K Agrawal Supply Chain Director for New Business Development
R S Subramaniam General Manager - Manufacturing Engineering and Projects
Anuradha Narasimhan Category Director - Health amp Wellness
Shalini Degan Category Director - Delight amp Lifestyle
T S Venketram General Manager - Manufacturing Development
Balaji Reddipalli Head Replenishment
R Anand Business Operations Director
Jehanagir Tankariwala General Manager - Human Resources
Vinod Menon Head of BNZF
Shridhar Panshikar National Sales Manager
P Govindan Company Secretary amp Head of Legal
Dr KN Shashikanth Corporate Quality Assurance Manager
V V Padnabham Corporate Manager -Information Systems
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1892 The Genesis - Britannia established with an investment of Rs 295 in Kolkata
1910 Advent of electricity sees operations mechanized 1921 Imported machinery introduced Britannia becomes
the first company East of the Suez to use gas ovens 1939 - 44 Sales rise exponentially to Rs1627202in 1939
During 1944 sales ramp up by more than eight times to reach Rs136 crore
1975 Britannia Biscuit Company takes over biscuit
distribution from Parrys
1978 Public issue - Indian shareholding crosses 60
1979 Re-christened Britannia Industries Ltd (BIL) 1983 Sales cross Rs100 crore 1989 The Executive Office relocated to Bangalore 1992 BIL celebrates its Platinum Jubilee 1993 Wadia Group acquires stake in ABIL UK and
becomes an equal partner with Groupe Danone in BIL
1994 Volumes cross 100000 tons of biscuits 1997 Re-birth - new corporate identity Eat Healthy
Think Better leads to new mission Make every
Milestones for the Company
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third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
Page 16Arpits
Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
Page 18Arpits
3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
Page 19Arpits
ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
Page 20Arpits
companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
BOARD OF DIRECTORS
Name Designation
Mr Nusli Neville Wadia Chairman
Ms Vinita Bali Managing Director
Mr AKHirjee Director
Dr Ajai Puri Director
Mr Avijit Deb Director
Mr Jeh N Wadia Director
Mr Keki Dadiseth Director
Mr Nasser Munjee Director
Mr Ness Nusli Wadia Director
Mr Nimesh N Kampani Director
Mr Pratap Khanna Director
Mr SSKelkar Director
Dr Vijay L Kelkar Director
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Management Team
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Gautam Banarjee General Manager(Materials)
A K Gupta General Manager - Accounts amp Planning
R K Agrawal Supply Chain Director for New Business Development
R S Subramaniam General Manager - Manufacturing Engineering and Projects
Anuradha Narasimhan Category Director - Health amp Wellness
Shalini Degan Category Director - Delight amp Lifestyle
T S Venketram General Manager - Manufacturing Development
Balaji Reddipalli Head Replenishment
R Anand Business Operations Director
Jehanagir Tankariwala General Manager - Human Resources
Vinod Menon Head of BNZF
Shridhar Panshikar National Sales Manager
P Govindan Company Secretary amp Head of Legal
Dr KN Shashikanth Corporate Quality Assurance Manager
V V Padnabham Corporate Manager -Information Systems
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1892 The Genesis - Britannia established with an investment of Rs 295 in Kolkata
1910 Advent of electricity sees operations mechanized 1921 Imported machinery introduced Britannia becomes
the first company East of the Suez to use gas ovens 1939 - 44 Sales rise exponentially to Rs1627202in 1939
During 1944 sales ramp up by more than eight times to reach Rs136 crore
1975 Britannia Biscuit Company takes over biscuit
distribution from Parrys
1978 Public issue - Indian shareholding crosses 60
1979 Re-christened Britannia Industries Ltd (BIL) 1983 Sales cross Rs100 crore 1989 The Executive Office relocated to Bangalore 1992 BIL celebrates its Platinum Jubilee 1993 Wadia Group acquires stake in ABIL UK and
becomes an equal partner with Groupe Danone in BIL
1994 Volumes cross 100000 tons of biscuits 1997 Re-birth - new corporate identity Eat Healthy
Think Better leads to new mission Make every
Milestones for the Company
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third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
Page 19Arpits
ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
Page 20Arpits
companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Management Team
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Gautam Banarjee General Manager(Materials)
A K Gupta General Manager - Accounts amp Planning
R K Agrawal Supply Chain Director for New Business Development
R S Subramaniam General Manager - Manufacturing Engineering and Projects
Anuradha Narasimhan Category Director - Health amp Wellness
Shalini Degan Category Director - Delight amp Lifestyle
T S Venketram General Manager - Manufacturing Development
Balaji Reddipalli Head Replenishment
R Anand Business Operations Director
Jehanagir Tankariwala General Manager - Human Resources
Vinod Menon Head of BNZF
Shridhar Panshikar National Sales Manager
P Govindan Company Secretary amp Head of Legal
Dr KN Shashikanth Corporate Quality Assurance Manager
V V Padnabham Corporate Manager -Information Systems
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1892 The Genesis - Britannia established with an investment of Rs 295 in Kolkata
1910 Advent of electricity sees operations mechanized 1921 Imported machinery introduced Britannia becomes
the first company East of the Suez to use gas ovens 1939 - 44 Sales rise exponentially to Rs1627202in 1939
During 1944 sales ramp up by more than eight times to reach Rs136 crore
1975 Britannia Biscuit Company takes over biscuit
distribution from Parrys
1978 Public issue - Indian shareholding crosses 60
1979 Re-christened Britannia Industries Ltd (BIL) 1983 Sales cross Rs100 crore 1989 The Executive Office relocated to Bangalore 1992 BIL celebrates its Platinum Jubilee 1993 Wadia Group acquires stake in ABIL UK and
becomes an equal partner with Groupe Danone in BIL
1994 Volumes cross 100000 tons of biscuits 1997 Re-birth - new corporate identity Eat Healthy
Think Better leads to new mission Make every
Milestones for the Company
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third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
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companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Gautam Banarjee General Manager(Materials)
A K Gupta General Manager - Accounts amp Planning
R K Agrawal Supply Chain Director for New Business Development
R S Subramaniam General Manager - Manufacturing Engineering and Projects
Anuradha Narasimhan Category Director - Health amp Wellness
Shalini Degan Category Director - Delight amp Lifestyle
T S Venketram General Manager - Manufacturing Development
Balaji Reddipalli Head Replenishment
R Anand Business Operations Director
Jehanagir Tankariwala General Manager - Human Resources
Vinod Menon Head of BNZF
Shridhar Panshikar National Sales Manager
P Govindan Company Secretary amp Head of Legal
Dr KN Shashikanth Corporate Quality Assurance Manager
V V Padnabham Corporate Manager -Information Systems
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1892 The Genesis - Britannia established with an investment of Rs 295 in Kolkata
1910 Advent of electricity sees operations mechanized 1921 Imported machinery introduced Britannia becomes
the first company East of the Suez to use gas ovens 1939 - 44 Sales rise exponentially to Rs1627202in 1939
During 1944 sales ramp up by more than eight times to reach Rs136 crore
1975 Britannia Biscuit Company takes over biscuit
distribution from Parrys
1978 Public issue - Indian shareholding crosses 60
1979 Re-christened Britannia Industries Ltd (BIL) 1983 Sales cross Rs100 crore 1989 The Executive Office relocated to Bangalore 1992 BIL celebrates its Platinum Jubilee 1993 Wadia Group acquires stake in ABIL UK and
becomes an equal partner with Groupe Danone in BIL
1994 Volumes cross 100000 tons of biscuits 1997 Re-birth - new corporate identity Eat Healthy
Think Better leads to new mission Make every
Milestones for the Company
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third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
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companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
1892 The Genesis - Britannia established with an investment of Rs 295 in Kolkata
1910 Advent of electricity sees operations mechanized 1921 Imported machinery introduced Britannia becomes
the first company East of the Suez to use gas ovens 1939 - 44 Sales rise exponentially to Rs1627202in 1939
During 1944 sales ramp up by more than eight times to reach Rs136 crore
1975 Britannia Biscuit Company takes over biscuit
distribution from Parrys
1978 Public issue - Indian shareholding crosses 60
1979 Re-christened Britannia Industries Ltd (BIL) 1983 Sales cross Rs100 crore 1989 The Executive Office relocated to Bangalore 1992 BIL celebrates its Platinum Jubilee 1993 Wadia Group acquires stake in ABIL UK and
becomes an equal partner with Groupe Danone in BIL
1994 Volumes cross 100000 tons of biscuits 1997 Re-birth - new corporate identity Eat Healthy
Think Better leads to new mission Make every
Milestones for the Company
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third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
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companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
third Indian a Britannia consumer
BIL enters the dairy products market
1999 Britannia Khao World Cup Jao - a major success Profit up by 37
2000 Forbes Global Ranking - Britannia among Top 300
small companies 2001 BIL ranked one of Indias biggest brands
No1 food brand of the country
Britannia Lagaan Match Indias most successful promotional activity of the year
Maska Chaska Indias most successful FMCG launch
2002 BIL launches joint venture with Fonterra the worlds second largest dairy company
Britannia New Zealand Foods Pvt Ltd Is born
Rated as One amongst the Top 200 Small Companies of the World by Forbes Global
Economic Times ranks BIL Indias 2nd Most Trusted Brand
Pure Magic -Winner of the Worldstar Asiastar and Indiastar award for packaging
2003 Treat Duet- most successful launch of the yearBritannia Khao World Cup Jao rocks the consumer lives yet again
2004 Britannia accorded the status of being a Superbrand
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Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
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companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Volumes cross 300000 tons of biscuits
Good Day adds a new variant - Choconut - in its range
2005 Re-birth of Tiger - Swasth Khao Tiger Ban Jaobecomes the popular chant
Britannia launched Greetings range of premium assorted gift packs
The new plant in Uttaranchal commissioned ahead of schedule
The launch of yet another exciting snacking option Britannia 50-50 Pepper Chakkar
2006 Britannia re-launched NutriChoice Hi-Fibre Digestive biscuits in an international large sized biscuit pack
Britannia acquires 51 stake in Bangalore-based bakery foods retailer Daily Bread
2007 Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial stake in the Dubai-based Strategic Foods International Co LLC and 654 in the Oman-based Al Sallan Food Industries Co SAOG Britannia NutriChoice SugarOut range introduced - 1st of its kind of biscuits to be be launched i India with No Added Sugar (Variants - Chocolate Cream Orange Cream and Litetime)
2008 Britannia NutriChoice 5 Grain biscuits launched - Biscuits with the goodness of 5 health Cereals and sweetened with Natural honey Britannia Nutrichoice promised consumers Bhook Bhagao Kuch Healthy Khao
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
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companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Britannia launched Iron fortified Tiger Banana biscuits Good Day Classic Cookies Low Fat Dahi and renovated MarieGold
2009 Britannia NutriChoice Nature Spice Crackers launched - Your favorite Cream Crackers now made even more exciting with the addition of Sabut Ajwain and Jeera spices
Britannia takes full control of Daily Bread
Britannia-Fonterra joint venture dairy business restructured Britannia acquires entire stake of Fonterra BNZF name changed to Britannia Dairy Pvt Ltd
Recognizing the changing global trends amp health benefits of removing transfats Britannia is the first Bakery brand in India to remove transfats from its products
Wadia Group acquired stake holdings from Group Danone and becomes the single largest shareholder in BIL
2010 Britannia NutriChoice launches a New Year pack - the Health Starter Kit Created for everyone who makes New Year resolutions and doesnt follow through The Health Starter Kit contains 1 pack each of NutriChoice Hi-FiberDigestiveNutriChoice 5 Grain NutriChoice Nature Spice Cracker bundled together with a Fit Sip Sipper and a fitness chart All this only for Rs 100
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
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companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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The reputation that Britannia has built over the years for high ethical standards is one of our greatest business assets To share the responsibility to preserve and enhance this asset the company has documented the Code of Business Conduct (COBC) for its employees
The COBC outlines the principles policies and laws that govern the activities of the company and to which employees of Britannia and others who work with or represent Britannia directly or indirectly must adhere The Code is distributed to all employees and directors and others associated with the business of the Company and offers guidance for professional conduct under six main headings which include the following key points
1 Responsibilities of Employees of Britannia
Maintaining ethical standards including appropriate accounting controls
Identify surface and resolve ethical issues with great speedCorporate assets (physical and intellectual) must not be used
for personal benefit Exercise good judgment and standards of good taste when
creating company records including e-mailMaintain company records accurately and retain them in
accordance with law
2 Workplace Responsibilities
Being committed to fair employment practicesBeing committed to a workplace free from drugs and any
kind of harassment or intimidation of employeesBeing committed to the safety of our employeesBeing committed to discipline at workplace Compliance with appropriate laws and internal regulations
Code Of Conduct of The Company(as provided to the employees)
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
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companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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3 Representing Britannia to Customers and Other External Constituencies
Treating customers suppliers and competitors fairly Maintaining high standards of quality Speeches media interviews and other public appearances in
connection with Britannia must first be approved internally Preparing accounts accurately and maintaining records Ensuring not to use unfair and misleading statements when
marketing Britannia products and services Accepting and giving gifts is not permitted except as
governed by the policy laid down herein
4 Privacy Confidentiality
Protect proprietary and confidential information at all times in accordance with applicable law
Keep customer information secure at all times as a sacred trust given to the company by our customers
Keep employees information confidential
5 Investments and Outside Activities
Trading in the securities of Britannia or any other company while in possession of inside information is illegal
Avoiding real or perceived conflicts of interest in areas including investments or outside business activities among others
6 Corporate Social Responsibility
Catering to the national interest Committed to be a good corporate citizen The company prohibits any payment of bribes
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
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companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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ADMINISTRATION OF THE CODE
DISTRIBUTION
All the directors of the company and employees will receive a copy of this Code at the time they join the company and will receive periodic updates Also any agent consultant government official or government employee who is retained by the company should receive this Code and understand the obligations under it
APPROVALS
The appropriate Principal Managers must review and approve in writing any circumstance requiring special permission as described in the Code Copies of these approvals should be maintained by the company and made available to auditors or investigating authorities
Waivers of any provision of this Code must be approved by the Board of Directors or its designated committee
MONITORING COMPLIANCE
Employees must take all responsible steps to prevent a Code violation
Employees should report suspected Code violations to their manager or higher level of management or to the corporate Legal and Internal Audit Departments In the case of potential criminal violations employees should inform the Compliance Officer
INVESTIGATIONS
The responsibility for administering the Code investigating violations of the Code and determining corrective and disciplinary action rests jointly with the Chief Executive Officer Chief Financial Officer and Compliance Officer alongwith the Audit Committee of the Board of Directors
The Compliance Officer may with the assistance of the
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companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
companys Internal Audit and Legal Departments conduct or manage investigations as deemed appropriate They will work together with the employees managers to recommend corrective and disciplinary actions for presentation to the Chief Executive Officer and the Chief Financial Officer For more information on the procedures that generally will be followed in the case of potential Code violations please refer to the Procedural Guidelines for the Code of Business Conduct
If allegations involve criminal conduct employees should seek guidance from the Compliance Officer before engaging in any inquiries
The Chief Financial Officer will report Code violations and the corrective actions taken to the Audit Committee of the Board of Directors
DISCIPLINARY ACTIONS
The company strives to impose disciplinary action for each Code violation that fits the nature and particular facts of the violation The company uses a system of progressive discipline The company generally will issue warnings or letters of reprimand for less significant first-time offenses Violations of a more serious nature may result in suspension without pay demotion loss or reduction of bonus or option awards or any combination thereof Termination of employment generally is reserved for conduct such as theft or other violations amounting to a breach of trust or for cases where a person has engaged in multiple violations
Violations of this Code are not the only basis for disciplinary action The company has additional policies and procedures governing conduct
SIGNATURE AND ACKNOWLEDGMENT
All new associates must sign an acknowledgement form confirming that they have read the Code and understand its provisions Failure to read the Code or to sign an acknowledgement form however does not excuse an associate from the terms of this
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Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Code
ITS UPTO YOU
Administration of the Code is everyones responsibility There are colleagues to help you do the right thing If you act with integrity and seek guidance when you are uncertain youll be doing the right thing
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Britannia -the biscuit leader with a history-has withstood the tests of time Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch With consumer democracy reaching new levels the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience variety and economy over and above health and nutrition
Britannia saw the writing on the wall Its Swasth Khao Tan Man Jagao (Eat Healthy Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty
Thus the new logo was born encapsulating the core essence of Britannia - healthy nutritious optimistic - and combining it with a delightful product range to offer variety and choice to consumers
The Origin of Eat Healthy Think Better
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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As we all are well aware about the company Britannia which has a huge product line well know about some of the products which arewere famous products of the company below
Cookies
Britannias latest symbol of Zindagi mein Life - Britannia Cookies is packed with the nourishment of wheat the richness of butter and milk and the lingering flavor of elaichi
Britannia is the leader in the cookies segment with the Good Day at the top end and now Britannia Cookies delighting consumers at the bottom end of the pyramid
The Britannia Cookie consumer is seeking to upgrade to a better taste experience but at an affordable price since biscuit category is considered as basic food and often consumed likewise Hence Britannia Cookies is priced at Rs5 for a10 biscuit pack
The brands TV commercial starring Deepti Naval as the mother taps into the universal meaning attached to food but
Product Line
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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reverse the common perception of the mother as the care giver Here the son packs Britannia Cookies for his mom in a bid to ensure that she eats something nourishing
The strategy was not to play up the pleasurable taste and indulgence that is normally associated with cookies but to highlight the health and nourishment that this product provides positioning it as healthy khaana
Summed up as Britannia Cookies - Tann ko lagey Mann ko chuay
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Tiger
Tiger launched in 1997 became the largest brand in Britannias portfolio in the very first year of its launch and continues to be so till today Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category
Tiger is a Glucose biscuit which comes with the added goodness of wheat and milk It is for modern mothers who play an enabling role for their children to compete in todays world and thus want the best Now Tiger Glucose has been fortified with Iron Zor with an attempt towards addressing the Iron Deficiency crisis the children of India face
Over the years Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India and transcending glucose biscuits
Tiger Coconut Delicious Coconut Flavoured Energy Biscuits launched in 2001
Tiger Creams Was Introduced in 2002 at just Rs 5 per pack Tiger Cream is now available in Orange Elaichi Chocolate Pineapple Strawberry and Butterscotch flavours and promises to bring more fun and more energy to children across the country
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Chota Tiger Is an extension of brand Tiger launched nationally in May 2007 It is mini sized poppable glucose biscuit with coloured sugar sprinkling It comes in two variants Milk Sparkies and Choco Sparkies
Tiger Banana Britannia is committed to help secure every childs right to Growth amp Development through good food everyday Purposefully taking forward the credo of Eat Healthy Think Better we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR amp and with the delightful taste of banana
IRON ZOR helps make mind sharper and body stronger A Rs4 pack has as much IRON ZOR as that in 1 kg of Banana
RampD in Britannia has spent considerable time to develop this nutritious and delightful snack for children
Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all being available in convenient packs priced at Rs2 Rs4 and Rs10
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Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Various products under Tiger family
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Good Day
Britannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter Over the years new variants were introduced - Good Day Pista Badam in 1989 Good Day Chocochips in 2000 and Good Day Choconut in 2004
This rich cookie enjoys a fan following of consumers across all ages loyal to the brand promise of a great taste evident from the visibly abundant ingredients Good Day is among the fastest growing brands in Britannias portfolio and it has been the leader in the cookies category ever since its launch The brand is synonymous with everyday treats that infuse happiness into peoples lives
After two decades of magnificent success it was time to give the nation yet another reason to have a good day Abundance goodness indulgence and now unrestrained joy - that is the message of this new campaign
The new TT ad is the uncontrollable expression of the ticket collectors happiness and joy that is stimulated by consumption of the cookie that spreads cheer amongst the people around him creating an atmosphere of shared joy thats unorchestrated and straight from the heart The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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each screaming and proclaiming Ho gaya re Good Day The dazzling brilliance of this endeavour the contagious rhythm needs to be lived and spread through the nation making Iska toh ho Gaya Re Good Day a part of the common lingo and a way of life
Good Day truly believes laughter and happiness are infectious it transcends race caste creed unifying humanity in an inclusive emotion
The brand perseveres to infuse cheer hearten the nation and enliven lives With its rightful place on the front page of The Times of India Good Day gifts the nation a priceless treasure that of spreading JOY
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Bourbon
Thick rich and delicious chocolate packed between two crunchy chocolate biscuits topped with sugar crystals - presenting the original Bourbon from the house of Britannia
Indias first and favorite Bourbons sweet adventure began in 1955 Since then Bourbon lovers across the country have been caught opening this chocolate couplet licking the cream and nibbling at the melt-in-your-mouth biscuit bit by bit Some have been witnessed chomping it whole at one go Some have been noted to alternate it with sips of coffee others team it with lots of gossip and gupshup while a few have been observed enjoying it with a book
And some have been seen reluctantly sharing their Bourbon
Whatever the occasion wherever the hangout Bourbon makes for great company You can grab your very own Nano Pack or a Pocket Pack The Hangout Pack is just right for chilling with friends Take along a Party Pack for yes a party And the Gift Pack will surely win you a few brownie points
So go on give yourself a happy high with a quick dose of Britannia Bourbon
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
50-50
With a brand name like 50-50 can the product be anything but fun Launched in 1993 50-50 belongs to the family of crackers and is considered the very very tasty tasty snack
Britannia 50-50 is the leader in its category with more than one-third of market share The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer As a result in 2001 the delicious Maska Chaska was launched as a variant of the original brand and became an instant success
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Marie Gold
Britannias oldest brand enjoys a heritage that spans 50 years - and going strong In a market swamped with Me too products Britannia Marie Gold has maintained its strong hold Today the ever popular Marie Gold is a loved brand that stands for Tea Time vitality Its balanced taste crispiness and lightness along with the added vitamins and minerals makes Britannia Marie Gold the healthy tea time biscuit It is the 1 brand in its category by a long shot
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Treat
As a move to consolidate all the individual Cream Treat offerings under a single umbrella Britannia launched Treat in 2002 Treat has a range of tasty delights for all kids with yummy creamy treasures within the biscuit shells The kids have always relished unraveling the irresistibly delicious creams hidden inside the biscuit Britannia Treat offers a wide variety of flavors such as the Elaichi the Fruit Flavored Creams such as Orange Pineapple Mango and Strawberry the Jam Filled Centers under the Jim Jam range and the Duet Range (biscuits with two flavours of cream between three layers of biscuit) comprising Strawberry Vanilla and Duet Strawberry Chocolate
Britannia Treat has now launched yet another mouth watering delight under its umbrella The delicious Fruit Rollz take the Treat brand beyond the cream biscuits and provides yet another lip smacking delight to its consumers
Fruit Rollz are soft rolls filled with the goodness of real fruits and provide a healthy yet scrumptious treat to our loveable devils Treat also introduced its naughty and adorable brand mascot FUNTOOSH whose primary occupation is mischief FUNTOOSH is the guy who will pull off any trick to make sure he gets to eat his Britannia Treat
For all you kids who have relished the yummy treasures of Britannia Treat in exciting flavors look out for yet another reason
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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to celebrate
Britannia Treat launches a new and exciting combination of chocolate and caramel in a single bar - TREAT CHOCO GELO This unique and never before product is guaranteed to double the masti and double the fun that you have with Treat
Treat Choco Gelo has been launched nationally in August 2007 and is available at an attractive price of just Rs5-
So go ahead open this delicious pack indulge yourself with Treat Choco Gelo and enjoy Yummy Chocolate and Gooey Caramel for Double Masti ka Double Dose
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Milk Bikis
Kids may dislike drinking milk but they love Britannia Milk Bikis Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their childrens nutrition regimen
In 1996 Milk Bikis launched a variant called Milk Cream These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children Milk Cream also promoted the idea of eating milk in a yummy way which makes mothers happy as well
To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form Milk Bikis went one step further in the last quarter of 2006 in providing not just energy but developmental fuel for children With a unique and attractive honeycomb design and an enhanced product experience the new biscuit is now fortified with SMART NUTRIENTS 4 vital vitamins iron and iodine proven to aid mental and physical development in growing kids
Britannia launched Milk Bikis Almond Cookies a first of its kind cookie with wholesome goodness of Milk amp Almond to help in growth and development of children
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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In-between-meals snacking is an integral part of a childs daily food routine as it serves as a hunger filler in between meals However most of the choices available in the market are universal in nature and largely address the delight needs of all consumers they do not necessarily provide the essential top up nutrition that children should have in their growing years Research conducted by Britannia showed that mothers would be happy to have a solution which is a good balance of nutrition for children in a snack format
With this in mind Britannia Industries Ltd one of Indias most trusted food brands with a diverse portfolio of products in biscuits bakery and dairy categories launched Milk Bikis Almond Cookie - with the wholesome goodness of Milk amp Almond in a delightful waffle cookie
Milk Bikis Almond Cookie contains milk and almond goodness important for childrens growth and development and comes in a cookie format which children will love to eat Four Milk Bikis Almond Cookies have the energy of one glass of milk and three almonds
Milk Bikis Almond Cookies have been launched initially in Tamil Nadu and will be available in Andhra Pradesh Priced at Rs12 per 885 gm pack and Rs25 for 193 gm Milk Bikis Almond Cookies are available with a shelf life of six months
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Time Pass
Before Timepass Britannias offering in the salted cracker category was Snax Launched in 1999 Snax was promoted as a tastier base for toppings through edgy advertising
Then in late 2000 supported by aggressive advertising that featured the brand as a perfect partner for timepass moments Britannia Timepass was launched
The brand quickly became a leader in Britannias portfolio and consequently Snax was revamped as a lighter product and renamed Britannia Timepass Classic Salted To further the franchise of the Timepass brand a variant Nimkee was introduced in the Eastern market in April 2003 and then taken nationwide after a favourable response Judging by its history the resounding success of Britannia Timepass will continue to grow
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
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73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Little Heart
Little Hearts was launched in 1993 and targeted the growing youth segment A completely unique product it was the first time biscuits were retailed in pouch packs like potato wafers The launch message introduced a special taste experience that made the unlikeliest characters - like Dracula and Frankenstein - melt In 1997 the Direct Dil Se campaign encouraged youngsters to openly express their feelings And in 2003 two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign Dil sabka actually sweet hai With Little Hearts Britannia has tasted the sweet taste of success
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Nice Time
Britannia Nice Time was the pioneer of sugar sprinkled biscuits in India This unique product managed to create such a strong consumer pull that soon there was a rush of pretender products in the market clearly indicative of the success of the concept Today Nice Time has a fan base spread across India and particularly East India where its consumers have grown up with the brand Especially popular amongst children Britannia Nice Time has managed to create a loyal franchise for itself and is a strong brand loved by people of all ages
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Nutri Choice
In continuation of the promise of Swasth Khao Tan Man Jagao Britannia introduced NutriChoice range of healthy biscuits in 1998 The brand is targeted towards overall health and wellness for adults
The range has for long comprised of three popular variants namely NutriChoice Thin Arrowroot NutriChoice Cream Cracker and NutriChoice Digestive
NutriChoice Thin Arrowroot - An ageless classicExtremely popular in East India for over 4 decades (where it is affectionately referred to as Britannia Theen) this brand contains the benefits of arrowroot known to aid digestion and remove harmful toxins from the body Prior to 1998 it was being marketed as Britannia Jacobs Thin
NutriChoice Cream Cracker - As nature would have wanted it to beAsk any biscuit manufacturer and they will tell you how difficult it is to make this biscuit especially with next to nothing sugar with NO added colors and flavorings for taste It is this neutral taste that makes it an ideal choice to be consumed with hot beverages dips chutneys and accompaniments
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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NutriChoice Digestive - Delightfully tasty and wholesomeMade with 50 whole-wheat and packed with added fibre (10 of our daily dietary needs) these delightfully tasty biscuits are amongst your healthiest bites of the day In your next visit to a shop just look out for its Golden-green international pack
In 2007 NutriChoice SugarOut was launched NutriChoice SugarOut is the most novel product range to have been introduced in the market The product is not just sweet but tastes great and yet contains no added sugar It is sweetened with Sucralose derived from sugar which provides the same sweetness as any other biscuit without the added calories of sugar
This range is available in 3 delicious variants namely Litetime Chocolate Cream and Orange Cream targeted towards all health sensitive people It is also relevant for consumers with sugar- related ailments
We are confident that you will be pleasantly surprised with the great tasting and healthy range of NutriChoice Try one and youll know that youve made one smart choice
NutriChoice 5 Grain
Most consumers believe that to in order to stay healthy one needs to make certain compromises on some good things in life Whether it is missing that extra hour of sleep over early morning exercise or eating unappetizing foods over that extra oil-dripping samosa At the same time most of us agree that good nutrition cannot come from one kind of food alone but from a healthy combination assortment of several healthy ingredients put together Britannia NutriChoice 5 Grain Biscuits are a perfect answer to those looking for healthy eating options without as much making a compromise on taste or convenience or health
Because Britannia NutriChoice 5 Grain biscuits are made from 5 carefully chosen healthy cereals (Oats that help reduce bad cholesterol Corn which promotes heart health Ragi a good source of both Calcium as well as Fibre Rice low in fat and Wheat that provides wholesome energy) These biscuits are delicately
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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sweetened with natural honey and come in a unique large oval shape It is this large size and the healthy combination of the ingredients that make it an ideal hunger buster for those in-between meals time hunger
Britannia NutriChoice 5 Grain biscuit pack contains several small single serve pocket meals packs so that one is never far away from pacifying hunger on the move So whenever you miss your breakfast or succumb to those unhealthy evening snacks you can relish the goodness of health with Britannia NutriChoice 5 Grain biscuits
NutriChoice Classic Lite Cracker - NutriChoice Crackers have for long been the healthy choice of the discerning consumer The popular NutriChoice Cream Cracker has been improved to make it crispier and tastier and been rechristened as Nutrichoice Classic Lite Cracker
NutriChoice Nature Spice Cracker - Now there is more choice for the discerning cracker consumer NutriChoice Nature Spice Crackers are delicately sprinkled with the goodness of Ajwain and Jeera Ajwain s benefit with good digestion is legendary while each one of us relishes the taste of Jeera In addition 0 Sugar is added to these biscuits which delivers the health promise that Nutrichoice is known for
NutriChoice Crackers are made by using a special FRESH BAKE TECHNOLOGY which ensures that they are completely free from Cholesterol harmful Transfats artificial preservatives colors and flavours They come in an international metalized packaging which ensures that the biscuits retain maximum freshness till the time they are opened
Nutrichoice Health Starter Kit2010 - Britannia Nutrichoice launches a New Year pack - the
Nutrichoice Health Starter Kit Created for everyone who makes a New Year resolution to become healthy and does not follow through on it The Health Starter Kit contains a range of healthy biscutis - 1 pack each of Nutrichoice Hi-Fiber Digestive Nutrichoice 5 Grain and Nutrichoice Nature Spice Cracker It also
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has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
has a one week free pass to Talalkars gym that entitles every consumer to one week free trial of any Talwalkars (TBVF ltd) gym across the country
In addition to this the pack also contains a Fit Sip Sipper and a fitness chart All this for only Rs 100
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
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Sweet or salty Soft or crunchy Simple or exotic Everybody loves munching on biscuits but do they know how biscuits began
The history of biscuits can be traced back to a recipe created by the Roman chef Apicius in which a thick paste of fine wheat flour was boiled and spread out on a plate When it had dried and hardened it was cut up and then fried until crisp then served with honey and pepper
The word Biscuit is derived from the Latin words Bis (meaning twice) and Coctus (meaning cooked or baked) The word Biscotti is also the generic term for cookies in Italian Back then biscuits were unleavened hard and thin wafers which because of their low water content were ideal food to store
As people started to explore the globe biscuits became the ideal travelling food since they stayed fresh for long periods The seafaring age thus witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries In fact the countries which led this seafaring charge such as those in Western Europe are the ones where biscuits are most popular even today Biscotti is said to have been a favorite of Christopher Columbus who discovered America
Making good biscuits is quite an art and history bears testimony to that During the 17th and 18th Centuries in Europe baking was a carefully controlled profession managed through a series of guilds or professional associations To become a baker one had to complete years of apprenticeship - working through the ranks of apprentice journeyman and finally master baker Not only this the amount and quality of biscuits baked were also carefully monitored
History of Biscuits
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The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
The English Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes They were often flavoured with nothing more than the finest butter sometimes with the addition of a few drops of rose water Cookies in America were also called by such names as jumbles plunkets and cry babies
As technology improved during the Industrial Revolution in the 19th century the price of sugar and flour dropped Chemical leavening agents such as baking soda became available and a profusion of cookie recipes occurred This led to the development of manufactured cookies
Interestingly as time has passed and despite more varieties becoming available the essential ingredients of biscuits havent changed - like soft wheat flour (which contains less protein than the flour used to bake bread) sugar and fats such as butter and oil Today though they are known by different names the world over people agree on one thing - nothing beats the biscuit
Some interesting facts on the origin of other forms of biscuits
The recipe for oval shaped cookies (that are also known as boudoir biscuits sponge biscuits sponge fingers Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called lady fingers when visiting Louis XV of France
The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution
SPRING-uhr-lee have been traditional Christmas cookies in Austria and Bavaria for centuries They are made from a simple egg flour and sugar dough and are usually rectangular in shape These cookies are made with a leavening agent called ammonium carbonate and baking ammonia
The inspiration for fortune cookies dates back to the 12th
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and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
and 13th Centuries when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders
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Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Manufacturing ProcessShort Dough biscuits manufacturing is a process involving
three phase of process line Pre Baking Baking Post Baking
The main raw materials are wheat flour sugar vegetable fat Food grade additives etc Dough is prepared using basic required ingredients then the dough is sheeted for continuous sheeter and cuted for required size and shapes After this process shaped biscuits are baked in the oven up to desired temperature and removed through conveyor here oil is sprayed on the biscuit to keep them shiny and more appealing After this process the biscuits are stacked using stacking unit and sent to packing machine for required type of packing
Machine Model List
Pre Baking machines
Sugar Grinder unit Sugar Syrup Machine Flour sifter Horizontal Dough mixer Horizontal cut and Lay Laminator Triple roll Sheeter (Three stage sheeter) Rotary Molding Machine Salt Sugar Sprinkler
Baking machine
Biscuit baking oven tunnel type
PRODUCTION
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Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Post baking machine
Turning Table Cooling conveyor Oil Spray Machines Stacker Machine
Packaging machines
Automatic Horizontal Flow Wrap Machine Automatic Horizontal Flow Wrap Machine with Auto Loader
for Biscuit (small Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Medium Pack) Automatic On Edge Horizontal Flow Wrap Machine with
Auto Loader for Biscuit (Family Pack)
Available Plant Capacity - 200 Kg per hour to 4000Kg per hour
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Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
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and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Biscuit Productin Line
Biscuit production line consists of following equipments with brief description-
MixersAll ingredients are mixed into mixers to prepare dough with
desired characteristics Normally two stage mixing is done in biscuit production One with rapid slow speed and second stage with rapid speed hence one select a dual speed mixer
Dough Elevator or Dough TipperDough bowl are either taken to tippers where dough is
decanted into mixer bowl which is beneath the tipper at level lower to the tipper or dough bowl is carried to certain height and then tilted to decant the bowl into laminator hopper
Dough LaminatorLaminator main function is to reduce the mass of dough into
uniform sheet or laminate for further reduction in gauge roll Laminators have sets of roller where this dough is acted upon and are converted into dough sheet
Gauge Rolls
These gauge rolls have set of cylindrical rollers which rotate in reverse direction so as to give push to the next gauge rolls Three stand to four stand of gauge rolls are used in normal biscuit production line Speed of rolls is set as per the baking time and increases as we proceed further
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Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Moulding or Cutter UnitThese are equipment which cuts the dough sheet into desired
shape and size Plant out put are calculated as per the design of the moulder or cutter These cutters or moulders have dies cups or inserts which are fixed on the cavities or surface of the moulder or cutter
Now days engraved moulders and cutters are available Moulders are now designed in rings instead of single piece which helps in maintenance or changing damaged cupsMolder are used for short dough where as cutters are used for hard dough variety
Scrap return conveyorThese conveyors returns the scrap dough back to mixers
which are again used for production thus minimizing waste
Swivel PannerSwivel panner is installed at the feed end of oven where it
centres the dough piece entrance on baking oven band it has swivel arrangement on which it balances the web or centres the web so that wet dough pieces enter s oven in straight line
Baking Oven Dough pieces then enters oven and travels on wire band for
baking Burners generate heat which is circulated through ducts or pipelines to bake wet dough pieces Length and width of oven are designed as per the capacity required Oven speed is adjusted as per the standards baking time for particular variety
Stripper ConveyorStripper conveyors are provided at the delivery end of oven
so that baked biscuit are cooled and doest not come into contact of any surface when hot A stripper conveyor has wire mesh which carries these hot baked biscuit
Cooling ConveyorThese conveyors are provided in biscuit production line to
bring down temperature of hot biscuits which comes out from oven Normally they 15 -2 times of oven length
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Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
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Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Magnetic StackerStacker are used to distributes and arrange biscuits in a line
and are thus could be stacked easily for packing process These biscuits are made to pass of plates which act as guides which makes these biscuits to fall into space between the guides
Packing TableBiscuit s travels into guidelines on packing table where
either they are fed into into packing machine automatically or are fed into feeding chutes manually by operators
Packing MachineBiscuits are fed into packing machine for packaging there
are various types of biscuit packing such as pile type on the edge and cream sandwich type Horizontal flow wrap machines are mostly used to pack with flexible packaging
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Dough Separating Device
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
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Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Short Dough Biscuits
Short dough biscuits are produced on lines which consist of a sheeter and calibration rollers After producing an endless dough sheet the desired dough blanks are cut by a single roller or double roller system The resulting network of scrap dough is fed back to the sheeter
The blanks are baked in a hybrid oven (directly heated in feed combined with radiation which can be provided with or without convection) on a wire mesh band
Dough Mixing
The HSM is used for preparing doughs for the production of dressed molded root-pressed (queen) and wire-cut biscuits hard and semi-hard biscuits as well as crackers
HSM - Technical Data Robust steel construction low noise vibration less stainless
steel panelling Kneading arms made of special steel supported on both
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High Speed Mixer(HSM)
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
sides All parts contacting dough made of non-rusting material Jacketed kneading bowl with thermo sensor for dough
tempering by means of water circulation up to 1500l = approx 900 kg doughbatch
Operating panel and switch cabinet integrated in machine frame
Sheeter
Three-Roller-Sheeter TRIOMAT
The TRIOMAT machines are used to produce uniform and homogenous dough bands of all common kinds of dough
TRIOMAT - Technical Data
All-steel two-plate construction Dough pulled in and pre-sheeted by fluted roller and upper
calibrating roller Dough band rolled out by upper and lower calibrating roller Conversion to calibrating machine possible by lowering the
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Triomat Sheeter
Preomat Sheeter
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
Page 73Arpits
Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
Page 75Arpits
Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
Page 76Arpits
Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
fluted roller Roller gap adjusted by motor with digital display Minimum dough band thicknesses of about 8-10 mm
possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Four-Roller-Sheeter PREOMAT
The PREOMAT machines serve to produce dough bands for rotary-cut biscuits or for feeding a biscuit molding machine respectively
PREOMAT - Technical Data
All-steel two-plate construction Fluted roller and calibration roller pairs with separate drives Roller gap adjusted by motor with digital display Fluted roller pair speed controlled by microprocessor Frequency-controlled three-phase motors as drives Minimum dough band thickness of about 4 mm possibleSpecial hopper arrangement return dough always fed to the bottom of the dough band therefore no surface color differences
Cutting Machines
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DuoCut
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
Page 66Arpits
ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Twin Roller Cutting Machine DUOCUTThe DUOCUT is used for the production of short dough
biscuits crackers and cocktail articles and can also be employed as single roller cutting machine
DUOCUT - Technical Data All-steel two-plate construction Independent drives for each roller cutting band and optional
moistening device Position of cutting rollers adjustable to each other Split bearings for simple installation and removal of the
rollers Bearing design allows use of several cutting rollers with
different diameters Cutting band with pneumatic band tensioning and band
centring
Pneumatic lowering of rubber roller for quick production interruption
On request available with integrated roller exchange system
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RotoCut
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
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5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
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Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
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Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
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Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
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Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
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Baking
4 Caramelisaion of sugar5 Dexterisation
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Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
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Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
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Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
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While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
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Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
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giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
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All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
ROTOCUTThe ROTOCUT simultaneously embosses and cuts dough
blanks out of a calibrated dough band by means of a cutting roller
ROTOCUT - Technical Data Centrally driven cutting band Bearing support design allows use of several cutting rollers
with different diameters Lowering of cutting roller by hand wheel Product changeover facilitated by simple removal and
installation of cutting roller Driven by frequency-controlled three-phase motor
Biscuit OvensThe Haas biscuit oven program allows the production of all
kinds of hard and short dough biscuits crackers and cocktail biscuits Swiss rolls or layer cakes The most suitable oven type for a certain product and for certain production conditions can be selected from different baking systems Moreover it is also possible to combine two different oven systems to a hybrid oven All ovens are available in working widths from 800 to 1600 mm
MULTIVARIANT OVEN - Technical Data Indirectly heated radiant oven Natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other
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Multivariant Oven
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
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Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
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ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
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Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
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Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
Page 69Arpits
5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
Page 70Arpits
Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
Page 71Arpits
Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
Page 72Arpits
Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
Page 73Arpits
Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
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In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
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Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
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Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
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Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
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Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
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This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
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Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
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Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Automatic ignition burner monitoring and temperature control
Optional addition of convection the advantages of indirectradiant heating (good product development universally applicable high moisture possible) are combined with those of convection (shorter baking times good drying low baking temperatures uniform product colouring)
CYCLOTHERM OVEN - Technical Data Indirect heating by natural or liquid gas or by heating oil 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control Centrally arranged high-capacity burner in each control
zone Heating of gases by a closed circulation system in the burner chamber gases are passed through ducts into radiators above and below the baking band
Page 65Arpits
Cyclotherm Oven
GasMultiburner Oven
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
Page 66Arpits
ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
Page 67Arpits
Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
Page 68Arpits
Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
Page 69Arpits
5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
Page 70Arpits
Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
Page 71Arpits
Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
Page 72Arpits
Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
Page 73Arpits
Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
Page 74Arpits
In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
Page 75Arpits
Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
Page 76Arpits
Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
GAS MULTI-BURNER OVEN - Technical Data Directly heated radiant oven Suitable for natural or liquid gas 20 m long modules with efficient rock wool insulation
welded baking chambers of carbon steel bolted to each other Automatic ignition burner monitoring and temperature
control 3-zone-burners (adjustable across the width) are specifically employed for uniform distribution of moisture and uniform product colouring across the width
ELECTRIC MULTI-BURNER OVEN - Technical Data Electrically heated by tubular radiators consisting of a
stainless steel tube enclosing a ceramic body with embedded resistance heating wires made of highly heat-resistant material
20 m long modules with efficient rock wool insulation welded baking chambers of carbon steel bolted to each other
Automatic ignition burner monitoring and temperature control
Infinitely variable thyristor control guarantees exact agreement of actual values with the set values
Steam extraction and discharge adjustable by manually operated dampers (placed every 5 m)
Page 66Arpits
ElectricMultiburner Oven
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
Page 67Arpits
Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
Page 68Arpits
Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
Page 69Arpits
5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
Page 70Arpits
Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
Page 71Arpits
Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
Page 72Arpits
Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
Page 73Arpits
Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
Page 74Arpits
In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
Page 75Arpits
Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
Page 76Arpits
Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Ingredients
The most common ingredients used in baking biscuits are following
FlourYeastFatSugarVitamin CBaking SodaBaking PowderSaltHydrogenated Vegetable OilSkimmed Milk PowderAmmonium Chloride
1 FLOUR - This provides most of the baked item For bread baking the flour should be a wheat flour which is high in gluten (protein) as this is substance that gives bread its fine texture and support the ingredients during rising The word flour refers to the powder obtained from grinding a cereal grain Although other flours (eg Rye flour) are used in baking wheat flour is by far the most common and is the only one that will be discussed here All flours are composed largely from starch and protein but wheat flour is distinctive in that it has very high levels of a class of proteins known collectively as gluten (8-14) When a dough is made from wheat flour and water the gluten develops into a thick cohesive elastic mass When placed in oven it puffs up to many times of its original volume and sets with a light airy texture This characteristic enables gluten to provide the structure in baked goods cakes and bread In the network of gluten the starch granules are embedded rather like a system of bricks in mortar The characteristic and general quality of the flour depend on The wheat variety and conditions under which the wheat has grown This affects the quality and quantity of gluten in the grain
The milling process This determines the degree of separation of the bran and endosperm as well as the particle size of the flour an important factor in cake flour
Page 67Arpits
Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
Page 68Arpits
Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
Page 69Arpits
5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
Page 70Arpits
Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
Page 71Arpits
Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
Page 72Arpits
Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
Page 73Arpits
Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
Page 74Arpits
In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
Page 75Arpits
Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
Page 76Arpits
Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Additives and special treatments used by the miller to produce flour mixes with special characteristics In New Zealand additives cannot be used in products sold as flour but they are commonly used by millers to make up premixes for particular applications
2 YEAST - Yeast is a plant that feeds on starch and sugars Releasing CO alcohol and sugar The CO bubbles give the dough 2 2
a light airy tecture Yeast is made up of many tiny singe-celled plants which grow bu budding each bud breaking away from the
oparent cell and warmth (Optimum 25-30 C) moisture and food (starch plus a small amount of sugar) Refrigeration slows down the growth so that yeast can be kept for a limited period of time When the yeast is used the conditions and the ls should be kept lukewarm to obtain the best results As soon as the yeast has been added to the dough or batter the yeast begins to feed on starch in the mixture forming sugar alcohol and carbon dioxide The bubbles of CO 2
cause the dough to expand(rise) The dough must be kneaded throughly to distribute the bubbles evenly and then left to rise again usually to about double its original volume If the mixture is left too long acid produced by the oxidation of the alcohol causes the product to taste sour
3FAT - Fat gives a softer texture and helps prevent the CO 2
bubbles from escaping from the mixture too soon Fat has five major roles in baking as outlined below How well it will perform each of these functions depends largely on the slip point - the temperature at which the fat just begins to melt In general the slip
opoint should be at least 5 C above the proving temperature of the dough
The Role of fat are as follows
Shortening
Fat weakens or shortens a dough by weakening its gluten network resulting in the baked product being softer breaking easily and having a more tender mouth feel
Page 68Arpits
Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
Page 69Arpits
5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
Page 70Arpits
Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
Page 71Arpits
Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
Page 72Arpits
Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
Page 73Arpits
Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
Page 74Arpits
In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
Page 75Arpits
Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
Page 76Arpits
Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Creaming
Fat can trap air during beating and mixing producing a batter that consists of masses of tiny air bubbles trapped within droplets of fat This is very important in cake baking in which it is these air bubbles that expand during baking forming a light airy structure
Layering
In puffy pastry fats which are soft over a wide temperature range are used These can be spread between pastry layers and will separate them during cooking giving a layered pastry
Flavor
Usually the fats used should have a bland flavor to prevent them from changing the flavor of the finished product but occasionally fats are chosen on the basis of their flavor- eg Using butter for particular baked goods and lard for meat pie pastry In addition the fat chosen needs to be able to form an emulsion with other ingredients in the batter or dough
4 SUGAR - Sugar provides a direct food source for the yeast improving its action Sugar is most commonly thought of as a sweetener but in baked goods it is also involved in several other processes Sugar undergoes a series of complex browning reactions
oabove 160 C and the products of these form the brown crust of many baked goods The reactions are known as mallard reactions and are essentially amino acid-catallysed caramelisation reactions in which a sugar aldehyde or ketone is converted to an unsaturated aldehyde or ketone
In addition 05-075 of sugar increases the rate of fermentation for fermented goods (ie breads) by giving the yeast more sugar to work on In non-fermented goods such as biscuits large quantities if sugar can be added This improves the keeping quality of the biscuits as well as sweetening them The sugar usually used is pure sucrose as castor sugar 1A sugar or icing sugar Occasionally impure forms such as golden syrup honey and brown sugar are used to give the baking a particular flavor
Page 69Arpits
5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
Page 70Arpits
Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
Page 71Arpits
Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
Page 72Arpits
Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
Page 73Arpits
Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
Page 74Arpits
In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
Page 75Arpits
Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
Page 76Arpits
Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
5 VITAMIN C - Also shortens the time needed for dough to mature It has been established from many experiments that the addition of a small amount (up to 100ppm) of vitamin C also shortens the time needed for the dough to mature This is because ascorbic acid catalyzes the gluten cross linking reactions to form a more extensible elastic strong network
6 BAKING SODA- Releases CO according to equation2
Since the material is relatively cheap and stable to store it would seem to be an excellent agent for the production of CO2 The above equation however also illustrates the disadvantages of the material When used on its own only half the available CO2 is released and more seriously the sodium carbonate produced is strongly alkaline and gives the baked product a bitter soapy taste and a yellow color The digestion of such products also tends to be somewhere between embarrassing and traumatic since the Na CO 2 3
reacts with the HCl in the stomach to produce the other half of the available CO For the above reasons it must be stressed that 2
sodium bicarbonate is very rarely used on its own but generally mixed with some acidic material such as cream of tartar honey cocoa or golden syrup (eg Treacle and baking soda are used together in baking gingerbread men) To avoid an imbalance between the acidic and basic materials ie an incorrect pH baking powder is more commonly used However as this also produces a strong base Na CO which has to be neutralized baking powder is 2 3
usually instead
7 BAKING POWDER - Baking powder is baking soda with acid added This neutralizes the base and produces more CO 2
according to the equation
8 SALT - Salt adds flavor and strengthens soft fat and sugar mixtures Salt is added to enhance the flavor of cakes and breads and to toughen up the soft mixture of fat and sugar
Page 70Arpits
Na CO + CO + H O2 3 2 22NaHCO3
+Na + H O + CO2 2
+NaHCO + H3
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
Page 71Arpits
Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
Page 72Arpits
Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
Page 73Arpits
Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
Page 74Arpits
In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
Page 75Arpits
Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
Page 76Arpits
Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
9 HYDROGENATED VEGETABLE OIL - (HVO)Main function of HVO is to retain the moisture inside the
dough Gives smoothness to the bite
10 SKIMMED MILK POWDER - (SMP) Main function of SMP is to give flavor to the product and sweeten the product
11 AMMONIUM CHLORIDE - Ammonium chloride provides nitrogen which is used to activate yeast in presence of water and sugar
Page 71Arpits
Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
Page 72Arpits
Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
Page 73Arpits
Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
Page 74Arpits
In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
Page 75Arpits
Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
Page 76Arpits
Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Ingredients Mixing Forming
LaminatorsGauge Rolls
Sheet ReductionCutter
MouldersShape and Sizeof dough piece
IngredientsAddition
Sugar SolutionPreparation of
FlourFat
AmmoniaAdditives
Flour sifterssugar grinders
MixersMixing Time
WaterCreaming
Doughconsistency
Biscuits grinders
Baking
Baking OvensBaking TimeTemperature
BurnersSteam Extraction
Oven Output
Cooling
Coiling TimeCooling
Conveyors
Packaging
PPMMetal Deduction
StackersFeeding ChuteHorizontal flow
form warpVertical filling
Creamsandwiching
WrapperPrinting
Carton Sealing
PRODUCTION process of Biscuits
Page 72Arpits
Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
Page 73Arpits
Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
Page 74Arpits
In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
Page 75Arpits
Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
Page 76Arpits
Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Mixing is a precess were all the ingredients are put together in right proportion for dough formation These ingredients are then fed into mixers where mixing is done and dough is prepared for molding Major ingredients are flour Fat Sugar and others as per the product one would like to have
These ingredients are used in varying proportions to produce different products As well as home baking these include commercial cake mixes and breads The commercial products and commercially produced raw ingredients are monitored in laboratories to ensure consistent quality and the New Zealand Institute For Crop and Food Research in Christchurch provides services for monitoring the composition of all wheat grown in New Zealand and all flours produced at flour mills The delicious smell and the delicious baking are produced as a result of the interaction of various chemical and physical processes that can be adjusted by the cook to create a great variety of products
Mixing can be done by following three types1 One Stage Mixing2 Two Stage Mixing3 Three Stage Mixing
1 One Stage Mixing - This type of mixing is used where all ingredients and water are added once Mixing is allowed till satisfactory dough is prepared Normally this type of mixing is used for hard dough This is also called All in One mixing
2 Two Stage Mixing -
First Stage is creaming In this stage all ingredients are added with water and mixed 4-5 minutes except flour
In second stage flour and chemicals are mixed with creaming product to form a consistent dough
Page 73Arpits
Mixing
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
Page 74Arpits
In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
Page 75Arpits
Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
Page 76Arpits
Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
3 Three Stage Mixing -In first stage fat sugar with other ingredients like milk
chocolate malt honey etc are mixed and cream is prepared with portion of water
In second stage salt chemicals and flavor with color are mixed with water
In third stage flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared
MIXING PROCESS -It has following characteristics which have been monitored
for better results
Mixing Time Normally any mixing could be achieved within 15-25 minutes Much depends on mixing speed of mixer flour characteristics or temperatures required for dough
Dough Temperature Very important factor the temperature o oranges between 35 C - 42 C as per biscuit variety
Dough Consistency This is done manually by checking dough and stretching the dough it should not break neither by bakers by trial and error method
For cracker variety dough are prepared which have additional ingredients like yeast and such dough are kept for 10 - 24 hrs
Page 74Arpits
In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
Page 75Arpits
Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
Page 76Arpits
Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
In forming section the dough is passed through several rollers to form sheet these sheets are than converted into one uniform sheet of desired thickness it is normally 5-6 mm thick
Molders and cutters are used to cut sheet or convert dough into desired shape and size
FORMING PROCESS -
Laminators -Dough after mixing is tipped into laminators hoppers are with some mechanicalpneumatic tilting There are two types of laminators
Horizontal Type Laminators- If space is not the constraint then horizontal type laminators are the best selection as the maintenance and repairs are easily done The lamination and the controls are visible Changing webs and rolls are very easy Pneumatics and servo motors are used in now modern day laminators for automated speed to be synchronized with rest of the plant which is around 11-14 sheets per batch
Vertical Type Laminators- Vertical type laminators have been there for very long its useful if space is a constraint Dough is passed through three stage rollers and after lamination of sheet it is cut into sheets which are then carried to rollers through inclined webs
Gauge Roll Stands- Reduction in sheet is achieved through numerous gauge roll stands Popular are three gauge rolls or four stand gauge rolls Reduction are achieved in stages an not to create too much stress on the sheet web is provided in between for relaxation even an additional web is provided prior to cutter to release stress from dough sheet Best results are achieved through four stand gauge rolls These gauge roll are of different diameter depending upon the plant capacity or requirement the different diameters are 6 8 10 12 amp 14 Speed is set as per the cutter
Page 75Arpits
Forming
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
Page 76Arpits
Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
RPM Gauge roll speed has to be increased in every stand so as to maintain the flow of sheets
Dough Sheet Conditioning- Dough sheet conditioning is done as per the ambient conditions in the plant
Steam Spray To moist the web surfaceBlower To dry the dough surface
Flour Dusting- To dry the wet surface of the dough This process is mainly for cutting variety
Toppings- Toppings are done through mechanical vibratory or spray a hopper is placed above the plant line after the cutter The toppings could be milk salt sugar or cashew pista bits
Rotary Cutter- Rotary cutters consists of cups which are attached to the cutter shell This shell is then fixed to the shaft and drive mechanism Two types of rollers are popular One is complete on mold shell where cups are attached in the cavity designed for with dowel pins Second concept is also very popular when shell has several rings fitted over it This helps in easy removal of damaged part and is also very helpful in taking various trials Cutter is coupled with the rubber of shore hardness of approx 80-85 Rubber roller or the pressure roller helps in releasing wet biscuits
RPM- Rotary cutter speed is set as per plant requirement baking time and variety of biscuit
Band Coverage Efficiency- It is ratio of total surface area of cutter-modulerno biscuit cups
Molding Roller- It is applied for short dough The dough is prepared in lumps these are then fed to die roll through either reciprocating conveyor to the hopper or a rotary conveyor which allows these dough crumbs to spread uniformly on the die roller surface These Die roller have dies engraved into it Dough pieces are then released by feed roller which pushes the dough into the dies
Page 76Arpits
Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Wet dough pieces of desired weight and shape are then passed on to oven band through swivel panner web Ovens are of different types classified into following categories
A Type of HeatingB Type of FuelC Type of DesignD Width of Oven BandE Number of Zones
Heat is transferred to biscuit on band through all the three ways of heat transfer ie conduction convection radiation Following are the chemical and physical changes which occurs in oven When dough piece is passed on to oven
Physical Changes
1 Formation of crust2 Melting of fat3 Gas expansion in dough piece due to CO2
4 Water converted into steam
Escape of gases and steam would result in collapse of biscuit structure hence these are passed onto different zones with gradual increase or decrease of temperature Zones are classified as
1 Heating Zone2 Baking Zone3 Coloring Zone
Chemical Changes
1 Gas formation2 Starch gelatization3 Protein changes
Page 7 7Arpits
Baking
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
4 Caramelisaion of sugar5 Dexterisation
Page 78Arpits
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Cooling process is as important than any other process When biscuits comes out from oven the temperature of biscuits are
oaround 70-95 C these biscuits can be cooled by letting it travel for distance of 15 times of baking time So if you have a oven of 200ft then the conveyor length would be approx 350ft In some places forced cooling is also done due to space constrain or for special features Cooling brings temperature to room temperature for handling of biscuits for packing
Page 79Arpits
Cooling
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Biscuits are fed into packing machines in continuos stacks this is either manual or with the help of auto feeders with help of feeding chutes Biscuits are fed into packing machines in continuous stacks this is achieved through stacker which converts free flowing biscuits into uniform stacks These are done through guidelines which could be adjusted as per type of biscuits
Major functionsadvantages of packaging are
Protect from mechanical damage in transit loading and unloading Protect from loss of moisture and any foreign odor contaminations Protect from foreign body infestation Legal compliance for values and ingredients for consumers Advertisement
Biscuits are wrapped with packing machines and wrappers are sealed as long and ends These are sealed with help of heaters Coders are synchronized with machine speed to print details to the packing material Packs could be of various size and shape Popular are pillow pack and family pack with weight ranging from 25gms to 400gms These packs are then put into cartons are been taped by passing through carton taping machines Now biscuits are ready for dispatch
Various type of packing material is used in biscuit industry
Primary packaging LaminateWrapper wax paper and Bopp films These are tailored made for various packs where the cut off length and width are decided prior to packing material production Basic properties for laminates and corrugated boxes are Bursting strength GSM and thickness of films measured in microns values varies from one product to other
Selections have to be done on above parameter Primary
Page 80Arpits
Packaging
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
function of packaging is protecting biscuit from foreign body infestation increasing shelf life product and manufacturer into and transportation
Technological innovation has made possible to have various shapes sizes and colors for biscuit packaging The important groups of packaging material are as follows-
Carton BoxesDisplay BoxesBopp ItemsWrapperStickersBopp TapesTear TapesShrink FilmsPolypropylene SheetsPouchesPVC TraysWax Papers
Page 81Arpits
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 What come to your mind when you think of biscuits___________________________________________
_______________________________________________
Q2 What do you look for when you purchase biscuits and cereals Please rate them on a scale of 1 to 5 (1being least important and 5 being Most Important)
Q 3 What is the major buying factors(tick any one)
Price Brand Name
Availability Discounts
Page 82Arpits
Attributes Importance
SizeNutrition Value
TasteCrispiness
IngredientsShape
ColorFlavor
PriceBrand Name
Questionnaire (External)
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Page 83
Q4 Which type of biscuits do you like to have(tick anyone)
Wafers Cream
Cookies Plain
Q5 Where do you make your purchase(tick any one)
Super Market Retailer
College Canteen Any Other
Q6 How many packets of Biscuits do you consume per
Week Month
Q7 Which Brand do you prefer(tick any one)
Britannia Parle
Kelloggs Lancer
Q8 If retailer gives you some other brand(other than you specified above) will you buy
Yes No
Q9 What improvements would you suggest for Britannia Biscuits_____________________________________________________________________________________________________________________________________________
Arpits
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Page 84
Please tell us something about yourself
Name
Age(yrs) (10-15)(15-20)(20-25)(25 amp above)
Sex(MF)
Household Income Level (12000-15000)(15000-20000)(20000-25000)(25000 amp above)
Occupation
Address
Arpits
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
73
27
Yes
No
This Questionnaire is for Academic purpose only and all the information revealed is collected by the trainee himself it has no link to the activities of the company
Q 1 As an employee of Britannia Industries Ltd are you satisfied with the working conditions here
Yes No
Q2 What more do you expect from the company______________________________________________________________________________________________
Q3 How much time do you spend in the company daily(in hrs)
6-8 8-10
10-12 12 amp above
Page 85Arpits
Questionnaire (Internal)
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
32
68
Yes
No
46
30
17
7
6-8 Hrs
8-10 Hrs
10-12 Hrs
12 amp Above Hrs
Page 86
Q4 What do you think you get paid enough according to the working time spent
Yes No
Q5 Are you satisfied with the services at the medical checkup conducted by the organization
Yes No
Arpits
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
17
83
Yes
No
88
12
Yes
No
Page 87Arpits
Q6 Is there anyone from your family working with Britannia Industries Ltd presently
Yes No
Q7 Would you prefer any of your relative to work with Britannia Industries Ltd
Yes No
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
31
16
37
16
Yes
No
Partially Satisfied
Partially Unsatisfied
67
33
Yes
No
Q8 Are you satisfied with the grievance resolution procedure of Britannia Industries Ltd
Yes No
Partially Partially Satisfied Unsatisfied
The data revealed here is collected by the trainee and has no link with the activities of the organization and is collected only for academic purpose it has nothing to do with the organizations actual activities
Page 88Arpits
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
While pursuing my training with Britannia Industries Ltd I came to know across various factors affecting the production system of a company running at a huge scale and after observing all the facts and figures I finally came to one huge question
How do they manage it all round the clock 24x7
And the answer to this question is very simple and well known It all depends on coordination and team work
Let me start from the very first day of my experiencewith the brand as a trainee I met with the HR Manager MrMayank Shreevastav he taught me a lot of things about thecompany itself and also about the corporate world to which I was unaware till that time his valuable suggestions and piece of knowledge also helped me a lot in completing my project work He showed me the way to his companys Production Manager Mr Anil Anand who was also my external guide for the period of my study and training he showed me all the departments and machines related to the production system in a step by step and well planned manner and it all took days as he also showed me the process at every stage for ex Laboratory tests of the raw material cleaning the machines preparing the mixers cutters and molders preparing the die for printing on the package as I was new to the organization I was not allowed there to wander on my own so I have to go where ever he took me or his presence was necessary at the point of time which helped me to know about the break downs
Page 81Arpits
Findings
Page 89
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
Page 90Arpits
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
and other problems faced in producing biscuits and also the method of resolving the problem which is impossibleto know through books or in lectures Well through my period of study I saw a lot of things to which Ill explain now
Quality Assurance- Now after being present at thecompanys production place as a trainee I can freely say that at Britannia the quality is at the highest priority starting from the very beginning when the raw material reaches its destination from various parts of the country as well as globe its first of all tested for the quality assurance and it is only than allowed to get into the production process when it is passed in the laboratory and if it fails the tests and very strictly followed guidelines of quality the whole consignment is rejected and is returned back to the supplier and a new and fresh consignment is ordered
Skilled and experienced employees- All te employeesworking at the Britannia are highly skilled and experienced not only with respect to their respective work assigned to them but they are also very handy with the other related tasks and works required
Clean and healthy Environment- Its not just about the raw material and the employees which makes the product good one of the very important factor related to quality production is environment at the work place the work place at Britannia is above average and the environment there is very friendly all the employees work as a team which results not in just good quality product but the rate of error becomes very low and the rate of use of resource is increased
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Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Right man for the right job- This policy is very helpful at every workplace to get the best from the human resource as if a person is assigned to a job to which he is very handy and better than other the efficiency of the individual as well as organization increases
State of the Art Technology- The manufacturing unit isequipped with the latest available technology and the bestavailable machines are used to produce the best qualitybiscuits latest available computer software is used to put acheck on machines and the production quality which doesnt just help in producing good quality products but also reduces the per unit economic cost and the wastage of precious resources is low which helps to increase the efficiency of the organization as a whole
Team Work- Above all is the team work all the employees at Britannia works as a team and the result is in front of us a well known brand with a variety of products available for the customer and with the major market share in every segment where the products of the brand is available and the trust on the brand proves it all in a way or the other we all use Britannia may it start with the breakfast at morning at our home or the tea time in the noon at officecolleges we all uses it in a way or the which proves that the team work of the employees works in the best manner it can not only at the production line but also at the distribution and marketing hand which makes it possible for the product to reach to the end customer or consumer no matter what the situation is
Limitations As we all know that noone and nothing is perfect so is the Britannia Industries Ltd even this huge
Page 91Arpits
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
giant of FMCG sector have limitations and is not flawless the total production process has some minute problems here and there all the time some time the manual and some time technical but it doesnt states that the organization is not working properly as I felt that the pungent smell goes directly to brain and is some times reduced by masks but the masks provided by the organization are not able to provide a complete cover to the smell which needs an attention the waste under process material is not able to use again ie it cannot be recycled as once all the ingredients are mixed they cannot be separated after preparation of the dough for this reason the organization has set a strict ratio of only 3 wastage but it still needs to be reviewed as the temperature of ovens is very high and
0is up to 100 C so the temperature of workplace around the ovens also increases and the employees working there needs a proper ventilationcooling system right over their head which is provided to them but doesnt seems proper to me
Page 92Arpits
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Page 93Arpits
All the data collected for generating this project report is collected from different sources these are
Company Journals Data provided by the project coordinator Notice Board the Pantnagar Unit
Company websites-wwwbritanniacoinwwwbritannialivingcouk
Other websiteswwwbiscuitseucomwwwwikipediaorg
Bibliography
Page 94
Page 94