The Islamia University of Bahawalpur Report Hafeez.pdf · introducing fruit squashes under the brand name of Mitchell's" Kissan". In 1947, as a result of emergence of Pakistan,

PROCESSING AND PHYSICOCHEMICAL

ANALYSIS OF GROCERY & CONFECTIONERY

PRODUCTS AT

MITCHELL’S FRUIT FARMS LIMITED RENALA KHURD, OKARA

By

Hammad Hafeez 2012-IU-603

Ahmad Raza 2012-IU-604

B.Sc (Hons) Agriculture

Department of Food Science & Technology

University College of Agriculture and Environmental

Sciences

The Islamia University of Bahawalpur

JUNE, 2016

PROCESSING AND PHYSICOCHEMICAL ANALYSIS OF FOOD PRODUCTS AT MITCHELL’S

2

Acknowledgement

All praises be to Allah who guides us in darkness and help in difficulties. If ocean

turn into ink and all of woods become pens even then the praises of Allah almighty

cannot be expressed. He, who created the universe and everything in the universe,

Nothing can happen without Allah permission and every one in universe is

answerable to him. Numerous blessing for Holy prophet (PBUH), who’s preaching

are right pathway for our success in the both lives.

My ineffable in deftness is due to Dr. Zulfiqar Ahmad (Assistant Professor)

Department of food science and technology, for his indelible patience to animate

my courage and providing all concern facilities magnificently.

This scholarly endeavor would have been futile without the cooperative attitude and

constructive minded and aluminous guidance of Dr. Muhammad Ammar Khan

(Lecturer) Department of food science and technology.

It is matter of great honor and pride for me to have the opportunity of internship in

the Mitchell’s fruit farms limited. I would like great gratitude for Mr. Shoaib Awan

(Production Manager) and Mr. Muhammad Idrees (Assistant Production Manager)

for their kind permission to complete my internship under their supervision.

Also special thanks to the Mitchell’s management and working staff for sincere

cooperation.

Last but not least, I feel pleasure to extend my heartfelt unlimited thanks to my

loving parents, dear brother and sisters for their moral and financial support and

countless prayers for my success.

Hammad Hafeez


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Dedication


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Table of Contents

1 INTRODUCTION 8

1.1 History of Mitchell’s fruit farms limited 8

1.2 Aim: 9

1.3 Vision: 9

1.4 Mission 9

1.5 Quality Policy 9

1.6 HACCP policy 10

1.7 GMP policy 10

1.8 ISO-9001 Certification 10

2 DEPARTMENTS AND ADMINISTRATION 11

2.1 Departments in Mitchell’s fruit farms ltd. 11

2.2 Management 11

3 MITCHELL’S PRODUCTS 12

3.1 Grocery products 12

3.2 Confectionary products 13

3.3 New Products 13

4 FACTORY TOUR 20

4.1 Sections 20

4.2 Important Machine Working in Processing Plant At MITCHELL’S 23

5 PRODUCTION DEPARTMENT 24

5.1 Grocery Section 24

5.1.1 Jaam-e-Hayat 24

5.1.2 Chili Garlic Sauce 25


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5.1.3 Chickpea 27

5.1.4 Golden Mist Marmalade 29

5.1.5 Mixed Fruit Jam 32

5.1.6 Orange squash 34

5.1.7 Saag 36

5.1.8 Ginger Garlic paste 36

5.1.9 Ginger paste 37

5.1.10 Apple jelly 37

5.2 Confectionary Section 40

5.2.1 Soft candy (Milk chocolate Éclairs) 40

5.2.2 Fruit Bon Bon (Hard candy) Orange flavor 42

5.2.3 Fruit Bon Bon (Hard candy) Strawberry flavor 42

5.3 Moulding Plant 43

5.3.1 Compound Chocolate 43

5.3.2 Happy Heart 44

5.3.3 Jubilee 45

5.4 Pulping Plant 47

5.4.1 Mango pulp 47

5.4.2 Mango pulp (Aseptic Filling) 49

6 QUALITY ASSURANCE DEPARTMENT 51

6.1 Laboratories 51

2) Incubation Lab: 51

6.2 Main Lab Tests 52

6.2.1 Determination of brix: 52

6.2.2 Determination of titrable acidity: 52

6.2.3 Determination of viscosity: 53

6.2.4 Determination of particle size: 53

6.2.5 Water hardness test 54

6.2.6 Water chlorine test 54

7 MY SPECIAL TASKS 55

7.1.1 Downtimes 55

7.1.2 Boilers 57

7.1.3 Water treatment plant 58

7.1.4 Overall Equipment Effectiveness (OEE) 59

7.1.5 Syrup Section 60

7.1.6 Weekly Progress Reports 61


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Abstract

Mitchell’s Fruit Farms is a public limited company. It focuses on the strategy of giving

consumers high quality products at low price. Mitchell’s follows focused differentiation. As their

target market is, all the people looking for quality products. The Production and Quality control

departments use different procedures for production and analysis of several products like jams,

ketchup, toffees, drinks and squashes. Sophisticated food processing machinery was installed and

additional products were added to a growing range of preserves, fruit, drinks, juices, canned

fruits, sauces and vinegar. I applied my theoretical knowledge into practical work. I learned how

to tackle with people in professional life.

During these eight weeks, I analyzed the work of Production department and Quality department.

I performed different analysis in production that is Filling Temperature Analysis of jams, jellies,

mango pulp and squashes. I also analyzed the temperature after cooling because it affects the

quality of the product during storage. I did work in Quality Control Department in which I

studied different quality parameters (pH, acidity, filling temperature, viscosity) of each product.

pH of Jam-e-Hayat, mixed fruit jam, chili garlic sauce and mango pulp was 72, 72, 45 and 17

respectively. Acidity of Jam-e-Hayat, mixed fruit jam and chili garlic sauce was 0.14, 0.64 and

2.5.


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1 INTRODUCTION

1.1 History of Mitchell’s fruit farms limited

Mitchell's fruit Farm Limited, was incorporated as a Joint stock Company in 1933 by

introducing fruit squashes under the brand name of Mitchell's" Kissan".

In 1947, as a result of emergence of Pakistan, Mitchell's lost three fourth of its market to India,

however the company readjusted and carved to a substantial niche in the new country. The

Mitchell's family sold majority of its shares to the Pakistani investor’s in 1957. Since then many

new chapters have been added to this story. Sophisticated food processing machinery was

installed and additional products were added to a growing range of preserves, fruit, drinks, juices,

canned fruits, sauces and vinegar.

In 1980 came the sweetest chapter of all with diversification on confectionery industry.

Soon Mitchell's confectionery products comprising toffee, eclairs, and hard candy and fruit

bonbon favor with nationwide.

In 1983 Mitchell's golden jubilee was celebrated with a fan fare and a chocolate bar,

appropriately named as "Jubilee” was launched to commemorate the event.

In the year of 1994 it was ISO certified. In 2001, Mitchell's launched moulded chocolate and

launched products like gift box of pralines, golden hearts and top milk was accepted by

consumer.


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1.2 Aim

It is aim at Mitchell's to provide you with healthy, innovative and best quality food that

will tempt your appetite at all times.

1.3 Vision

1) To be market leader in this industry by keeping in view the importance of healthy

hygienic nutrition food to customer for their delightness.

2) To be a company which optimally combines its people, technology, management systems

and market opportunities to achieve profitable growth while providing fair returns to its

shareholder.

1.4 Mission

1) To be a leader in the markets, we serve by providing quality products to our consumers

while learning from their feedback to set even higher standards.

2) To be a company that continuously enhances its period technological skills to remain

internationally competitive in this day and age of increasing challenges.

3) To be a company that attracts and retains competent peoples by creating a culture that

foster innovations, promotes individual growth and rewards initiative and performance.

4) To be a company which optimally combines its people, technology, management system

and market opportunities to achieve profitable growth while providing fair returns to

shareholders.

5) To be a company that endeavors to set the highest standards in corporate ethics.

1.5 Quality Policy

We, at Mitchell’s fruit farms ltd, aim to be a leader in market we serve by providing quality

products to our customers while learning from their feedback to set even higher standards.

Our goals are –

a) To be a company that continuously to superior technological skills to remain competitive

in national and international markets in this day age of increasing challenges.

b) To be a company that attracts and retains competent peoples by creating a culture that

foster innovations, promotes individual growth and rewards initiative and performance.


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c) To be a company which optimally combines its people, technology, management system

and market opportunities to achieve profitable growth while providing fair returns to

shareholders.

d) To be a company that endeavors to set the highest standards in corporate ethics and

fulfills its social responsibility.

1.6 HACCP policy

Our consumer’s health and well being is of prime importance to us; that’s why we are in the

process of introducing HACCP- A systematic approach to control all kinds of hazards at critical

points during processing.

We do this to win and maintain consumers-confidence.

1.7 GMP policy

Mitchell’s is committed to manufacture safe and high quality products.

We ensure food safety by paying attention to the following:

1) The quality of our product and processing.

2) Effectiveness of our sanitation programs.

3) Hygiene practices of our employees.

1.8 ISO-9001 Certification

Mitchell’s, a name synonymous with quality, taste and trust for over 78 years, gained, in 1998,

another distinction: ISO 9001 certification. And at no better time, than the successful completion

of 78 years. It is a matter of immense pride and honor for the Company that Mitchell’s has

become the first food company in Pakistan to achieve this prestigious distinction. What makes it

more significant is the fact that ISO 9001 involves all steps in the manufacturing chain; starting

from designing and development of products to production, right up to distribution. Thus the

Company, guided by its professional management, makes every effort to ensure that the product

reaches the consumer’s table just as promised: farm-fresh and maintaining the highest levels of

quality.


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2 DEPARTMENTS AND ADMINISTRATION

2.1 Departments in Mitchell’s fruit farms ltd.

Following are departments in Mitchell’s Fruits Farms Limited:

1) Marketing department

2) Sales department

3) Commercial department

4) Accounts & Finance

5) Production department

6) Planning and storage department

7) Technical services department

8) Quality assurance department

9) Human resource department

10) Research & Development department

2.2 Management

Managing Director Mr. Mian Mohsin

General Manager Mr. M. Mujeeb

Factory Manager Mr. Shoaib Awan

Department HOD

Production Mr. Shoaib Awan

Engineering Mr. Iftikhar

Store Mr. M. Shokat

Sales Mr. Haji Habib

Purchase Mr. Nadeem

Security Mr. Farquleet Zafar

H.R. Department Mr. Shaikh Naveed


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3 MITCHELL’S PRODUCTS

With nine categories encompassing over 140 products, we are proud to present the Mitchell's

family - products to grace your dining table on the breakfast and dinner occasions as well as

products to appease your sweet tooth.

3.1

Total Products: 15

Total Products: 22

Total Products: 20

Total Products: 19

Total Products: 13

Total Products: 17


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Total Products: 2

3.2

Total Products: 22

Total Products: 10

3.3 New Products

1) Fruit Punch

Extending its existing product line of Fruit Drinks, Mitchell's has introduced an irresistible

combination of Fruits in a drink as Mitchell's Fruit Punch. So now you can enjoy the taste of not

only one but many fruits in a single drink.


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2) Fruitica Orange (Instant Drink)

Keeping in view the increasing demand of powdered drinks, Mitchell's has launched its powder

instant drinks range in 25gm Sachets. The ideal thirst quenchers will be available in Orange

flavour.

3) Fruitica Lime (Instant Drink)

Keeping in view the increasing demand of powdered drinks, Mitchell's has launched its powder

instant drinks range in 25gm Sachets. The ideal thirst quenchers will be available in Lime flavor

4) Yum! Ketchup Stand-up Pouch (500g)

Mitchell's has launched its existing Yum! Ketchup in 500g stand-up pouch for the convenience

and economy of its consumers

5) Top Milk Fruit & Nut

A superb combination of Fruit & Nuts with Milk Chocolate to indulge your sweet-tooth.


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6) Luxuree 30g

Enjoy a taste of the exotic tropical! Luxuree is a wonderful treat consisting of a pure, white

coconut core wrapped in rich, milky smooth chocolate.

7) Luxuree 8g

Enjoy a taste of the exotic tropical! Luxuree is a wonderful treat consisting of a pure, white

coconut core wrapped in rich, milky smooth chocolate.

8) Apple Jelly Junior

Mitchell's has launched its classic preserves in smaller packaging, i.e., 200g Jars, so that you can

enjoy more flavours in lower price.

9) Golden Mist Marmalade Junior


enjoy more flavors in lower price.

10) Strawberry Jam Junior




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11) Mixed Fruit Jam Junior


enjoy more flavours in lower price.

12) Mango Jam Junior



13) Golden Apple Jam Junior



14) Hot & Sweet Sauce

Neither too sweet nor too spicy, Mitchell's has introduced a delicious combination of Tomatoes

and Chilies with the name of Mitchell's Hot & Sweet Sauce.


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15) Synthetic White Vinegar

In addition to its pure Fruit Vinegar, Mitchell's is also launching Synthetic White Vinegar, which

can be taken with soups and garnishing of salads. Moreover, it can be used from being a food

enhancer or condiment, to meat tenderizer and natural food preservative.

16) Yum! Ketchup Stand-up Pouch

Mitchell's has introduced a new variant of Ketchup with the name of "Mitchell's YUM! Ketchup".

The delicious ketchup will be an excellent treat for the consumers in economical price.

17) Lychee Fruit Drink

Mitchell's Fruit Drinks are made from real fruits picked from its own gardens that will refresh

your body and soul. Keeping in view the increasing demand of fruit drinks flavours, Mitchell's

has launched another refreshing flavour, Lychee Fruit Drink, in its respective category.

18) Jaam-e-Hayat


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Keeping in view the growing demand of Red Syrups, Mitchell's has launched New Red Syrup in

810ml and 1.5Litres Pet Bottles. Be ready to taste the refreshing experience.

19) Apple Fruit Drink

Mitchell's Fruit Drinks are made from real fruits picked from its own gardens that will refresh

your body and soul. Keeping in view the increasing demand of fruit drinks flavours, Mitchell's

has launched another refreshing flavour, Apple Fruit Drink, in its respective category.

20) Mango Hyderabadi Pickle

We can safely guarantee for the fact that no meal is complete without Mitchell's Pickles!

Hyderabadi Pickles are a delicate assortment of fruits and vegetables matured through natural

processes, and carefully selected spices, made in a truly traditional way and carrying an authentic

homemade flavor. New, mouth watering recipes are constantly being formulated to complement

the existing range.

21) Mixed Hyderabadi Pickle

We can safely guarantee for the fact that no meal is complete without Mitchell's Pickles!

Hyderabadi Pickles are a delicate assortment of fruits and vegetables matured through natural

processes, and carefully selected spices, made in a truly traditional way and carrying an authentic

homemade flavour. New, mouth watering recipes are constantly being formulated to complement

the existing range.

22) Anniversary


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To commemorate the company's Platinum Jubilee, we take great pride in the launch of

Anniversary - a delectable selection of chocolates especially created for the discerning consumer

- as our way of saying "Thank You" to our loyal clientele for their support and patronage

spanning three generations.

23) Spinach Puree

Spinach Puree is made from the freshest spinach leaves and packed in tin can. Open the can to

cook and prepare a delicious meal with either vegetables like Potatoes, or with meat. You just

need to add spices and oil to cook. It can be eaten with Bread, Paratha or Rice.

Spinach Puree is packed in 800gms cans for the pure convenience of consumers.

24) Super Milk Toffees

Mitchell's new Super Milk Toffees are bigger in size and better in taste than any other Milk

Toffees, which will bring lots of fun and excitement for you to share with your friends and

family.


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4 FACTORY TOUR

4.1 Sections

Publicity Board visible from Renala Khurd Bypass while

heading towards Lahore Aerial View of Mitchell's Factory

Factory Offices Factory Offices

Conference Room Quality Control Lab


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Micro-biological Lab Chocolate Conching Machine

Molded Chocolate Plant Enrobed Chocolate Plant

Squashes & Drinks Filling Machine Sugar Confectionery Section


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Toffee & Hard Candy Wrapping Machine Precision Weighing Machine in Sugar

Confectionery Section

Sauces Filler Preserves Filler

2 Views of Groceries Section

Can Retort Automatic Can Seamer


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4.2 Important Machine Working in Processing Plant At MITCHELL’S

Machine Company Country Product

Pasteurizer NKR engineering (Pvt) ltd Syrup

Thermo break Ing. A. Rossi Italy Pulp

Candy blower HANSELLA Candy

Candy Rope Former BOSCH Germany Candy

Trans wraps machine BOSCH Nederland Jar labels

Pouch making & filling BOSSAR Spain Ketchup

Shrink wrap machine Smipack Jars, Bottles

Glass bottle Labeling LANGGUTH Bottles

10g/100g pouches Sama Engineering Pakistan Ketchups

Stephan mixer Stephan machinery Germany Pastes

Blancher JIAHAO technology company ltd. China Saag, Chickpea

Can Retort STERINOV France Saag, Chickpea

Glass jar filling Cft packaging Jams, Jellies

Evaporator Ing. A. Rossi Pulp

PET conveyors & labeling Esleeve Sauces

Wrapping machine (jars) Portovantovano MN Italy Jams, Jellies

Coding Machines Domino A400& A220 All products

Candy twist wrap (old) Nageema Germany Candies

Candy twist wrap (new) P.M Italy Candies

Gas Boilers Heavy Mechanical complex ltd. Pakistan ---

PET filling machine Zilli& Bellini Sauces

Lab Equipments Parameter

Hardness test kit MERCK Germany Water Hardness

Chlorine testing kit HANNA instruments Rumania Chlorine

Hardness testing kit HANNA instruments Rumania Hardness

Viscometer Brookfield Viscosity

TDS meter MARTINI instruments TDS

pH meter HANNA instruments Rumania pH

Weighing balance Accurate scale system Weight

Moisture analyzer Sartorius % moisture

Refractometer HANNA instruments Rumania Brix


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5 PRODUCTION DEPARTMENT

5.1 Grocery Section

5.1.1 Jaam-e-Hayat

Ingredients

Sugar, glucose syrup, citric acid, sodium benzoate, polysucralose, Natural

Extracts; Rose, ushna, aniseed, kewra, color. Procedure

1) Issue all the ingredients required for Jaam-e-Hayat from grocery and confectionary

store.

2) Take sugar and make sugar syrup of 80 brix.

3) Store Sugar syrup Into a storage tank for a specific time .

4) Transfer the syrup to a mixing tank and all natural extracts add to it.

5) Heat the syrup for a specific time then send it to filler.

6) PET bottles washed by a pressurized water spray in washer.

7) Fill the bottles with Product through the filler at 60˚C filling temperature.

8) After filling, Capper put the caps on the bottles and sealed them.

9) Cooling took place in cooling tunnel.

10) Progressively , Labeling, Coding and secondary packaging occurred.

Quality Analysis (Jam-e-hayat)

Date Parameters F1 F2 F3 F4 F5 F6 Average

24/6/2015 Brix 72 72 71 72 71 72 71.67±0.52

Acidity 0.16 0.14 0.15 0.14 0.13 0.14 0.14±0.01

27/6/2015 Brix 72 72 71 72 71 72 71.67±0.52

Acidity 0.14 0.16 0.14 0.14 0.14 0.14 0.14±0.01

11/7/2015 Brix 72 71 72 72 71 72 71.67±0.52

Acidity 0.15 0.14 0.15 0.14 0.14 0.14 0.14±0.01

17/7/2015 Brix 72 72 72 72 71 72 71.83±0.41

Acidity 0.14 0.15 0.16 0.14 0.14 0.15 0.15±0.01

22/7/2015 Brix 71 72 71 72 72 72 71.67±0.52

Acidity 0.17 0.16 0.15 0.14 0.14 0.15 0.15±0.01

Quality Standards

˚Brix 72

Acidity% 0.14


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5.1.2 Chili Garlic Sauce

Ingredients

Vinegar, Vitamin C, Red Chili powder, Salt, Sodium benzoate, Sugar, Thick flow Powder,

Tomato concentrate, Garlic powder, Xanthin gum, Color. Procedure

1) Issue all the ingredients required for Chilli Garlic Sauce from grocery and

confectionary store.

2) Make a mixture sodium benzoate, Xanthin gum, vitamin C and add it into water in

chemical mixer at above 90˚ C for 20-25 minutes.

3) Prepare sugar syrup in syrup room and add other ingredients into it and transfer to

vacuum pan.

4) Add chemical mixture into a vacuum pan after required ˚Brix is obtained.

5) Transfer the product to Bossar Machine’s filler and automatically fill the pouches.

6) After filling, top sealing, cooling, drying and secondary packaging has been

performed.


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Quality Analysis (Chili Garlic Sauce)


6/7/2015

Brix 45 45 45 46 45 46 45.33±0.52

Acidity 2.54 2.5 2.55 2.55 2.49 2.54 2.53±0.03

Viscosity 2550 2490 2470 2465 2500 2500 2495.83±30.40

8/7/2015

Brix 45 45 45 45 45 45 45.00±0.00

Acidity 2.4 2.49 2.52 2.55 2.53 2.56 2.51±0.06

Viscosity 2520 2510 2510 2520 2525 2550 2522.50±14.75

13/7/2015

Brix 45 46 45 46 45 46 45.50±0.55

Acidity 2.54 2.49 2.47 2.44 2.57 2.52 2.51±0.05

Viscosity 2490 2490 2490 2470 2540 2590 2511.67±44.91

17/7/2015

Brix 45 45 45 46 45 45 45.17±0.41

Acidity 2.44 2.46 2.54 2.54 2.56 2.53 2.51±0.05

Viscosity 2505 2510 2510 2510 2530 2510 2512.50±8.80

2/8/2015

Brix 45 45 45 46 45 45 45.17±0.41

Acidity 2.55 2.54 2.53 2.45 2.44 2.47 2.50±0.05

Viscosity 2510 2505 2490 2490 2510 2520 2504.17±12.01

Quality Standards

˚Brix 45

Acidity% 2.5

Viscosity (cps) 2500


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Flow Diagram

5.1.3 Chickpea

Ingredients:

Water, Salt, Chickpea

Procedure:

1) Issue chickpeas from grocery store.

2) Chickpeas soak in water tank for at least 4 hours.

3) After which these are put into Blancher which is working at 100˚C and completes one

turn in about 25 minutes.

4) Blanched chickpeas are weighed and fill in cans manually.

5) Then brine solution of 2-3 ˚Brix is filled by filler in remaining space.

6) Filled cans are passed through a closed conveyer which provides heat of 100˚C by hot

air.


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7) Tops are sealed by sealing machine before in-pack sterilization.

Retort Functioning

Venting 66-100˚C 3 minutes

Heating 109-126˚C 8 minutes

Sterilization 126˚C 15 minutes

Precooling 100-90˚C 6 minutes

Cooling 70-30˚C 35 minutes

Flow Diagram


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5.1.4 Golden Mist Marmalade

Ingredients

Orange concentrate, Vitamin C, Citric Acid, Pectin, Sugar, Sodium Citrate, Orange

flavor, Grape Fruit Juice, Orange Shred.

Procedure

1) Issue all the ingredients required for GMM from grocery and confectionary store.

2) Take 120 kg shredded orange peel and blanch it.

3) Take 1200 kg Sugar and make the sugar syrup of 80˚Brix.

4) Take 40 kg Grape fruit juice and 10 kg orange concentrate.

5) Dilute the grape fruit juice with water and achieve a 2-3˚Brix and give the stay time of

one day which results in settle down of fiber and other coarse material.

6) Cleared floating juice is separated out and mix with the sugar syrup.

7) Make a mixture of sodium citrate, pectin and vitamin C and add it into water in

chemical mixer at 90˚C for 25- 30 minutes.

8) Add syrup with shred in vacuum pan and create the vacuum 600 mmHg and set the

temperature at 100˚C.

9) When we achieve 75-76˚Brix, stop heating and add chemical mixture, color, flavor

and citric acid.

10) Start heating again and create vacuum.

11) After completion of process, pour the product into storage tank until all entire product

consumed on the filler.

12) Fill the glass jars with product at 80˚C of filling temperature.

13) Progressively, capping, inspection, cooling, labeling, coding and secondary

packaging (shrink wrap) has been performed.

14) Then final product stored in go down.

Workers on line and their Placement

Placement Number of Workers

Chemical room 02

Sugar syrup preparation 03

Juice feeders 03


30

Cooking 04

Jar feeders 04

Filler 01

Capper 01

Inspection 02

Labeling 02

Label checker 01

Printer 01

Secondary packaging 06

Juice transfer 01

Total workers 31

Quality Analysis


25/6/2015

Brix 72 72 71 71 72 72 71.67±0.52

Acidity 0.65 0.61 0.62 0.65 0.64 0.64 0.64±0.02

Filling Temp. 75 76 76 79 77 76 76.50±1.38

29/6/2015

Brix 71 72 71 72 71 72 71.50±0.55

Acidity 0.65 0.61 0.62 0.63 0.64 0.64 0.63±0.01

Filling Temp. 76 76 75 74 76 76 75.50±0.84

7/7/2015

Brix 72 71 72 72 71 72 71.67±0.52

Acidity 0.65 0.64 0.63 0.66 0.62 0.64 0.64±0.01

Filling Temp. 72 76 74 75 75 76 74.67±1.51

15/7/2015

Brix 72 72 72 72 71 72 71.83±0.41

Acidity 0.64 0.63 0.63 0.56 0.62 0.64 0.62±0.03

Filling Temp. 75 76 75 75 75 76 75.33±0.52

19/7/2015

Brix 72 72 71 72 72 72 71.83±0.41

Acidity 0.65 0.64 0.63 0.66 0.62 0.64 0.64±0.01

Filling Temp. 75 76 74 74 74 76 74.83±0.98

Quality Standards

˚Brix 72

Acidity% 0.65

Filling Temperature 75


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5.1.5 Mixed Fruit Jam

Ingredients

Sugar, Apple Pulp, Mango Juice Pulp (With Chemical), Mango Juice Pulp (AC),

Orange Concentrate, Citric Acid, Pectin, Sodium Benzoate, Vitamin C.

Procedure

1. Issue all the ingredients required for mixed fruit jam from grocery and confectionary

store.

2. Take the Raw apple, mango and orange.

3. Wash them and make pulp through the pulper.

4. Take sugar and make sugar syrup of 80 ˚Brix.

5. Mix fruit pulp with sugar syrup.

6. Make a mixture of sodium benzoate ,pectin , vitamin C and add it into a water in

chemical mixer at above 90 ˚C for 20-25 minutes.

7. Transfer the syrup into the vacuum pan and create the vacuum of 600 bars and set the

temperature at 100 ˚C for 45 minutes.

8. When we achieve our required brix add chemical mixture and citric acid.

9. After completion of cooking, transfer the product into the storage tank.

10. Fill jar with product through the filler at 80 ˚C of filling temperature.

11. Progressively, capping, inspection, cooling, labeling, coding, and secondary

packaging (Shrink wrap) has been Performed.

12. Then final product stored in go down.

Workers and Their Placement

Point No. of workers

Juice feeding 03

Syrup Preparation 03

Syrup Juice Mixing 01

Chemical Mixer 02

Vacuum Pan 04

Jar Feeder 04

Filler 01


33

Capper 01

Screening 03

Labeling 02

Label Checker 02

Printer 01

Secondary packing 07

Total Workers 33

Quality Standards

Brix 72

Acidity 0.64


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5.1.6 Orange squash

Ingredients

Citrus pulp, Sugar, Citric acid, Carboxy methyl cellulose (CMC), Potassium meta bisulphate

(KMS), Salt

Procedure

The juice is shifted in juice mixing tank, mix CMC and salt in hot water. Add this

mixture to the juice and mixing is done. This juice is pumped to sugar mixing room in which two

stainless steel tanks are mixing. Then sugar is added in the juice while continually mixing the

tank. Add KMS and citric acid in the juice. Mix all the ingredients till 40 Brix. Then this mixture

is passed through a pulper which separates all the solid materials from squash. This pulper is

equipped with a very fine sieve having mesh size less than 10. Squash is passed through

Homogenizer that homogenizes the mixture completely. Then it is transferred to the filler where

it is filled in PET bottles, capping and washing of bottles is done then after labeling and coding

bottles are packed in cartoons and stored in finish goods store from where product in marketed.

Quality Analysis


9/7/2015 Brix 41 41 40 41 40 40 40.50±0.55

Acidity 1.65 1.63 1.63 1.66 1.59 1.63 1.63±0.02

10/7/2015 Brix 42 41 41 40 42 40 41.00±0.89

Acidity 1.66 1.65 1.65 1.64 1.66 1.65 1.65±0.01

25/7/2015 Brix 40 40 41 40 40 41 40.33±0.52

Acidity 1.66 1.65 1.65 1.65 1.66 1.65 1.65±0.01

3/8/2015 Brix 39 40 41 40 40 40 40.00±0.63

Acidity 1.65 1.65 1.65 1.66 1.65 1.67 1.66±0.01

10/8/2015 Brix 40 40 41 40 40 40 40.17±0.41

Acidity 1.67 1.67 1.66 1.65 1.65 1.65 1.66±0.01

Quality Standards

Brix 40

Acidity 1.65


35

Flow Diagram


36

5.1.7 Saag

Ingredients

Saag, Spinach, Green pepper, Corn flour, Salt

Procedure

1) Take 80 kg saag and 20 kg spinach, wash it combine and cut with cutter machines.

2) Blanch it at 100˚C for 25 minutes in blancher.

3) Add green pepper, corn flour and salt in Stephan mixer and grind it.

4) Pour the processed material into a storage tank and provide steam within it to avoid

heat loss and fouling problem during filling.

5) Material transfer to the filler from storage tank and fill the cans at filling temperature

75˚C and speed of 67 cpm.

6) After filling of cans, upper seal of can is inserted by steam pressure which seals them

through a seamer.

7) Then cans are filled into iron pallets to insert them into a Retort. In retort following

operations occur.

8) Sterilized cans then stored for labeling when required.

Retort Functioning

Venting 66-100˚C 3 minutes

Heating 109-126˚C 8 minutes

Sterilization 126˚C 65 minutes

Precooling 100-90˚C 12 minutes

Cooling 70-30˚C 40 minutes

5.1.8 Ginger Garlic paste

Ingredients

Ginger, Garlic, Vegetable oil, Modified starch, Acetic acid, Salt, Potassium Met bisulphate,

sodium benzoate, Vitamin C, Water.

Procedure

1) Take all the ingredients from the grocery store.

2) Put all the ingredients into Stephan mixer and close the pan.


37

3) Mix the ingredients at 80˚C and create a vacuum of 700 mbar and running time of

machine is 13 minutes.

4) The final product should have 11˚Brix.

5) After that, Paste transfer to the preserve line where filling process is done.

6) Progressively, filling, capping, precooling, cooling, inspection, drying, coding, labeling

and secondary packaging occurred.

5.1.9 Ginger paste

Ingredients:

Ginger, Vegetable oil, Modified starch, Acetic acid, Salt, Potassium Met bisulphate, sodium

benzoate, Vitamin C.

Procedure:

1) Take all the ingredients from the grocery store.

2) Put all the ingredients into Stephan mixer (150kg) and close the pan.

3) Mix the ingredients at 90˚C and create a vacuum of 700 mbar and running time of

machine is 07 minutes.

4) The ˚Brix of final product should be 8.

5) After that, Paste transfer to the preserve line where filling process is done.

6) Progressively, filling, capping, precooling, cooling, inspection, drying, coding, labeling

and secondary packaging occurred.

5.1.10 Apple jelly

Ingredients:

Vitamin C, Citric Acid, Pectin, Sugar, Allura red (Color), Apple flavor, Apple pulp,

Sunset yellow (color)

Procedure:

1) Issue all the ingredients required for Apple jelly from grocery and confectionary store.

2) Take Sugar and make the sugar syrup of 80˚Brix.

3) Take apple pulp and dilute it with water and achieve a 2-3˚Brix and give the stay time of

one day which results in settle down of fiber and other coarse material.


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4) Cleared floating juice is separated out and mix with the sugar syrup.

5) Make a mixture of, pectin and vitamin C and add it into water in chemical mixer at 90˚C

for 25- 30 minutes.

6) Add syrup in vacuum pan and create the vacuum 600 mmHg and set the temperature at

100˚C.

7) When we achieve 72˚Brix, stop heating and add chemical mixture, color, flavor and citric

acid.

8) Start heating again and create vacuum.

9) After completion of process, pour the product into storage tank until all entire product

consumed on the filler.

10) Fill the glass jars with product at 85˚C of filling temperature.

11) Progressively, capping, inspection, cooling, labeling, coding and secondary packaging

(shrink wrap) has been performed.

12) Then final product stored in go down.


39


40

5.2 Confectionary Section

5.2.1 Soft candy (Milk chocolate Éclairs)

Ingredients:

SMP, water, starch powder, glucose, sugar, lecithin, salt, butter flavor, caramel, caramel color,

condensed milk flavor, vanillin, calcium, coconut oil, chocolate, butter cream flavor.

Procedure:

1) Take milk, water, salt and starch powder and prepare it in a pan.

2) Take fat and lecithin and make a mixture by heating with steam.

3) Sugar is inserted into sugar tank and glucose in a glucose storage tank.

4) All above ingredients (Point 1-3) combines in a mixing and heating chamber.

5) From where it is transferred to a storage vessel in which continuous agitation occur.

6) Then this whole material cooked in a cooker at 116˚C for 30-35 minutes.

7) Cooked material poured on water cooled plates (cooking oil and starch powder used as

propellants) where it gains required consistency.

8) Material divides in bulk parts which can easily inserted into Batch Former (a machine).

9) Batch former shifted the shape of material into lower diameter by its rollers and transfer

the material to Rope Former.

10) A chocolate pump inserts the chocolate into batch through a pipe.

11) Rope former convert the shape into a rope at 4 stages. Every stage thickens the rope and

last couple of disk gives our required size.

12) Next process is cutting by a cutter or dye.

13) Blower blows the cool air on a 2 storey conveyor on which cut ropes are spread.

14) Twist wrapping is done in wrapping machines. Average speed of wrapping is 500 candies

/ minute.

15) In secondary packaging, every pouch contains 43 candies and every carton contains 36

pouches.

Check list for Soft Candy

Cooking temperature 116˚C

Unit weight 3.2 g

Chocolate filling Ok

Wrapping quality Ok


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Seal Ok

Coding Ok

Number of candy /pouch 43

Line CIP Ok

Hygienic conditions Ok

Area Temperature 24.5˚C

Area humidity 36%

Flow Diagram


42

5.2.2 Fruit Bon Bon (Hard candy) Orange flavor

Ingredients:

Sugar, Glucose, Citric Acid, Orange oil, Color mix, Apple jam

Detail:

We worked on Fruit Bon Bon processing line and observe the whole procedure of hard candy

manufacturing.

Its start from the mixing of sugar and glucose which is heated at 142˚C for 4 minutes after which

it acquires strength of hard candy which is inserted into a flavor mixer and all the chemicals

including color and flavors are added thoroughly.

Then prepared material put on the cooled plates and then inserted into batch former.

A fruit jam is filled into the material by a filling pipe which takes the jam from a drum by the

force of a feed pump.

Batch former push the material into rope former after which it cuts into required length of toffee

and passed through a blower which cool it down make it hard.

Wrapping and secondary packaging is done afterwards.

5.2.3 Fruit Bon Bon (Hard candy) Strawberry flavor

Ingredients:

Sugar, Glucose, Citric Acid, Strawberry flavor, Color mix, Apple jam

Detail:

Today we worked on Fruit Bon Bon processing line and observe the whole procedure of hard

candy manufacturing.

Its start from the mixing of sugar and glucose which is heated at 142˚C for 4 minutes after which

it acquires strength of hard candy which is inserted into a flavor mixer and all the chemicals

including color and flavors are added thoroughly.

Then prepared material put on the cooled plates and then inserted into batch former.

A fruit jam is filled into the material by a filling pipe which takes the jam from a drum by the

force of a feed pump.

Batch former push the material into rope former after which it cuts into required length of toffee

and passed through a blower which cool it down make it hard.

Wrapping and secondary packaging is done afterwards.


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5.3 Moulding Plant

5.3.1 Compound Chocolate

Ingredients:

Sugar, Vegetable fat, Skimmed milk powder, Cocoa Powder, Lecithin, Artificial flavor

Procedure:

1) Issue all the ingredients from grocery & Confectionary store.

2) Take sugar, vegetable fat, SMP and cocoa powder in mixer and mix it at 45˚C for 15 -20

minutes which will give a product particle size of 45 µ. Its capacity is 450 kg.

3) Transfer the material to the refiner which has 5 rollers which has different temperature

and converts the particle size to 24 µ.Its capacity is 150 kg.

4) Then material tends to the conch which mix it for 8 hours regularly during which

Artificial flavor, lecithin and remaining fat is added. Its capacity is 6 tones.

5) After that process, product is transferred to storage tank which is double injected and hot

water circulates into it until the chocolate is consumed.

Quality Analysis (Chocolate)


24/6/2015 Viscosity 4945 4900 5000 5050 5037 4760 4948.67±108.34

Particle size 24 24 24 24 23 24 23.83±0.41

27/6/2015 Viscosity 5035 5120 5040 5100 5000 5040 5055.83±44.99

Particle size 23 23 24 24 24 24 23.67±0.52

11/7/2015 Viscosity 4900 5240 4990 5000 4990 5020 5023.33±113.96

Particle size 23 24 22 25 24 23 23.50±1.05

17/7/2015 Viscosity 4790 4760 4700 4970 4905 4990 4852.50±119.32

Particle size 24 23 24 24 23 24 23.67±0.52

22/7/2015 Viscosity 4917 4990 5000 5090 4970 5005 4995.33±56.36

Particle size 24 24 23 25 23 24 23.83±0.75

Quality Standards

Viscosity (cps) 5000

Particle size (µ) 24


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5.3.2 Happy Heart

All pure chocolate products are manufactured in molding plant.

Ingredients:

Compound Chocolate, Rice crispy

Procedure:

Whole procedure and manufacturing line of happy Heart is mentioned below


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5.3.3 Jubilee

Ingredients Composition

Nougatine Hyfoama Versa whip*

Salt

Ground Sugar

Water

Fat mix Cocoa powder

Skimmed milk powder

Socfat**

Syrup Sugar

Glucose

Water

Caramel Glucose, milk powder, water, salt, sugar, socfat, calcium,

lecithin,

Chocolate SMP, CBS***, sugar, cocoa powder, lecithin, vanillin****,

condensed milk flavor, butter flavor, chocolate cream flavor

*hydrolysed soy proteins (combined vegetable proteins) which expand at specific temperature.

** Socfat trans free shortening is a palm based blended fat specially texturized to impart plasticity and

smooth consistency that facilitate mixing and ease of us at ambient temperatures.

***cocoa butter substitute.

**** Vanillin is a phenolic aldehyde

Procedure:

1) Take ingredients for Nougatine preparation from grocery and confectionary store.

2) Prepare hyfoama by mixing versa whip, salt, sugar and water in defined quantities and

heat them at 79˚C (Company standards = 80˚C)

3) Prepare fat mix by mixing cocoa powder, skimmed milk powder and socfat at same

conditions as hyfoama.

4) Prepare syrup by mixing (180 minutes) water with glucose and sugar at same conditions.

5) Combine all three recipe in a mixing tank and product is called Nougatine .

6) Take ingredients for caramel and prepare caramel by cooking at 113˚C for 30-35 minutes.

7) Prepare Compound chocolate by mixing all ingredients in chocolate room.

8) Transfer nougatine and caramel to their specific feeders at conbar machine.

9) Lower layer is of nougatine and upper layer is caramel and both will combine and pass

through first cooling tunnel.


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10) After this dividers divide this material into layers of our required width.

11) Cutters will cut the layers into small pieces of specified length.

12) Chocolate enrobers provide the coating of chocolate to the product then coated conbar

will pass through second cooling tunnel.

13) Product is ready to pack on wrap machine.

Jubilee Flow Diagram


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5.4 Pulping Plant

5.4.1 Mango pulp

Ingredients:-

Mangoes, Citric acid, Ascorbic acid, Sodium Meta bisulphate

Procedure:-

1) Take fresh raw mangoes from the garden and put on the conveyor where sorting is

performed manually by workers.

2) Graded mangoes move on elevator conveyor and drop into a washing conveyor.

3) After washing with cold water, transfer the mangoes to the sorting conveyor (691 rpm)

where rollers of about 3 inches in diameter rotate the mangoes and facilitate the workers

to pick up the undesirable mangoes.

4) Next is the brush conveyor contains a series of brushes, rotates, wash and remove the

dust at a time.

5) Now our cleaned mangoes are ready for processing in destoners (which operate at 85˚C)

which removes all the mango stones and maximum peel.

6) The raw pulp goes into a tank from where it moves to hot break (A heat exchanger)

works at 95˚C.

7) Then Pulp moves to the pulper (working speed 80%, mesh 1.25mm, 1885 rpm) which

homogenize the material and next moves to refiner.

8) Pulp refiner (mesh0.8mm) removes all the fiber and remaining peel particles.

9) Refined pulp store in a storage tank which has the capacity of about 3000 liters.

10) When storage tank completely fill, juice transfers to the pasteurizer by passing through

the filters (0.05mm).

11) After pasteurization at 90˚C juice is stored in a mixing tank where chemicals are mixed to

preserve the mango juice for direct use or manufacturing of other products like jams.


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49

5.4.2 Mango pulp (Aseptic Filling)

Ingredients:-

Mangoes, Citric acid, Ascorbic acid,

Procedure:-

1) Take fresh raw mangoes from the garden and put on the conveyor where sorting is

performed manually by workers.

2) Graded mangoes move on elevator conveyor and drop into a washing conveyor.

3) After washing with cold water, transfer the mangoes to the sorting conveyor (691 rpm)

where rollers of about 3 inches in diameter rotate the mangoes and facilitate the workers

to pick up the undesirable mangoes.

4) Next is the brush conveyor contains a series of brushes, rotates, wash and remove the

dust at a time.

5) Now our cleaned mangoes are ready for processing in destoners (which operate at 85˚C)

which removes all the mango stones and maximum peel by providing steam.

6) The raw pulp goes into a tank from where it moves to Thermal break (A heat exchanger)

works at 95˚C .The function of thermal break is to soft the pulp.

7) Then Pulp moves to the pulper (working speed 80%, mesh 1.25mm, 1885 rpm) which

homogenize the material and next moves to refiner.

8) Pulp refiner (mesh0.8mm) removes all the fiber and remaining peel particles.

9) After that refined pulp moves to filter and at this stage ˚Brix of product is approximately

20.

10) Pulp moves to Evaporation plant which consists of two effect evaporator system.

11) Pulp firstly enter into 2nd

effect evaporator where it circulates and moves to first effect

evaporator by first circulating pump where steam is provided to heat the pulp at 65˚C.

12) Vapors of first effect evaporator moves to the second effect evaporator which is the

source of heat in 2nd

effect evaporator.

13) Remaining vapors moves to the condenser where cold water turns them into liquid state

and tends to the cooling tower.

14) After achieving 28˚Brix of the pulp, it moves to the deareator, then to the homogenizer

(19 bars).


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15) After homogenization, pulp moves to the sterilizer where sterilization takes place for 40

minutes at 110˚C.

16) Product is suddenly cooled by chilled water (10˚C) which cools down the product at 35˚C.

17) Now product is ready to fill the pouches under Aseptic conditions and moves to the filler

and fills the pouches aseptically.

18) Finally pouches are placed into drums which are stored for a long while.

Flow Diagram


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6 QUALITY ASSURANCE DEPARTMENT

6.1 Laboratories

There are 5 labs which are as follows

1) Main lab

2) R& D lab

3) Incubation lab

4) Microbiology lab

5) Line control lab

1) Main Lab:

All the incoming raw materials are tested for their predefined Mitchell’s quality

standards. If the incoming raw material full fills the quality requirements then the product is

passed if not then the product is failed and returned to supplier as no compromise on quality

inputs. Viscosity of products, pH & TDS of boiler water are tested and a daily report is sent to

the Boiler Engineer. pH, Acidity of jams and jellies. Moisture %age. Particle size is tested. Li,

Na & K is tested in ppm with the help of flame photometer. FCMP is tested in main lab and

incoming glucose is tested in the main lab Vacuum testing of the canned products is tested in the

main lab.

2) Incubation Lab:

Samples are taken from the line from production section and these samples as one

sample per batch is tested and kept in the incubation lab chronically for two years and studied for

their behavior in storage. If any complain comes from market about product then the product that

comes from market is compared for its quality with the reference sample from the incubation lab

of the same batch code.

3) Line Control Lab:

This is very critical lab for checking the online production in the grocery hall for

its best defined quality. The instrument that is used in the lab is calibrated according to the ISO

standards. The titratable acidity, Brix and filling temperature of the product is noted if it matches

with the predefined standards then well and good if not then the production supervisor is given

the suitable suggestions to adjust the acidity , Brix and filling temperature.


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4) R& D Lab:

The products that are prepared by the R & D section are evaluated by the sensory

evaluation panel in the sensory evaluation lab and a Performa is given to the panelists and a blind

evaluation is done and their observations are recorded in the sensory evaluation Performa and

submitted to QAM.

5) Microbiology Lab:

Microorganisms’ plays very important role not only deteriorates the products but

also create health hazardous. Microbial testing is carried out to determine safety of workers,

products and process and working environment. Moreover water and Air microbial load is also

checked on monthly basis. All microbiology tests are carried out in micro lab.

6.2 Main Lab Tests

6.2.1 Determination of Brix:

Objective: To determine the amount of total soluble solids in products.

Scope: Jam, Jellies, Marmalades, Sauces, Juices, Squashes, Drinks, Pulps, Ketchup etc.

Apparatus: Refractometer, Light source (Lamp), and Distilled water (for calibration)

Procedure:

1) Calibrate the Refractometer it should show “Zero” reading of distilled water at 20 C.

2) Apply the thin layer of product on Refractometer slide.

3) Observe reading through lens by adjusting the shade with help of knob.

4) Note reading %. Clean the Refractometer slide with water.

6.2.2 Determination of titrable acidity:

Objective: To determine the Acidity of Products either as citric acid, acetic acid or lactic acid.

Scope: Almost all grocery products

Reagents: 1 % Phenolphthalein, 0 .1 N NaOH

Procedure:

1) Take sample in conical flask

2) Add some water for uniform stirring

3) Add 3-4 drops of phenolphthalein

4) Titillate against 0.1 N NaOH


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5) Light pink color is end point

6) Stop titration & note the reading

Calculation:

For Citric Acid = ml of (0.1 N) NaOH used X 0.64

Weight of sample

For Acetic Acid = ml of (0.1N) NaOH used X 0.60

Weight of sample

For Lactic Acid = ml of (0.1N) NaOH used X 0.009

Weight of sample

6.2.3 Determination of viscosity:

Viscosity: It is the resistance to flow

Scope: Sauces, Melted chocolate, Syrup, chutneys, pasts etc.

Apparatus: Brookfield Viscometer

Procedure:

1) Dip the specific number spindle in the sample

2) Turn on the viscometer by adjusting its speed. Speed in rpm.

3) Reading is taken by pushing the speed button & power button simultaneously.

4) Hold the speed button until reading is taken.

5) Spindle & Speed in rpm, specify a factor “f” and dial reading is “d” is noted. Viscosity is

calculated as

F x d = Viscosity in centipoises

Precaution: Viscosity should be checked at 50 C.

Chocolate viscosity stander = 7000 + 1000 cps

6.2.4 Determination of particle size:

Objective: To determine the particle size of products e.g. chocolate.

Scope: Chocolate & all other products in which particle size maintenance are necessary

to improve the texture & uniformity.


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Apparatus: Elcometer or Micrometer

Procedure:

1) For calibration, rotate its screw until it touches to the opposite side.

2) At this point reading on the screw.

3) Slowly move the cylinder until both parts touch each other.

4) Note reading, it’s in mm. Convert it in microns for chocolate.

Chocolate particles size sander = 25 um

Precaution: Before particles size determination cleans the micrometer properly.

6.2.5 Water hardness test

Object: To determine Hardness of water

Scope: Boiler water, Treated water, Waste water, Feed water

Apparatus: Hardness Kit

Procedure:

1) Take 5ml sample of water to be test.

2) Add 3 drops of H-1 solution which convert its color to bright red.

3) Add H-2 solution drop by drop and stir the sample continuously.

4) Red color converts to greenish color it will be its end point.

5) Note the reading on the dropper that how much H2 solution is used.

6) This value will be Hardness of Water

6.2.6 Water chlorine test

Object: To determine Residual chlorine in water

Scope: Boiler water, Treated water, Waste water, Feed water

Apparatus: Chlorine Kit

Procedure:

1) A chlorine kit consists of two parts in which one part contain standard color and values

and second one in which we take sample.

2) Take 5ml sample of water in chlorine kit.

3) Add 3 drops of NaOH reagents And 5 drops of H2SO4 reagents.

4) These reagents will change the color of water which resemble one of the standard color

and that is the value of chlorine in water.


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7 MY SPECIAL TASKS

7.1.1 Downtimes

The time during in which a machine is out of action or unavailable for use is called downtime.

Purpose

To calculate our real total production in comparison with ideal production.

Types

According to Mitchell’s standards there are two types of Downtimes.

1) Major downtimes; Stoppage of more than 10 minutes

2) Minor downtimes; Stoppage of less than 10 minutes or 10 minutes

Further downtimes are classified technically as

1) Electrical stoppages

2) Mechanical stoppages

3) Utility stoppages

4) Supply chain stoppages

Working

1) We worked on processing lines to calculate all minor and major stoppages.

2) Sum up all minor and major, electrical, mechanical and utility stoppages.

3) Subtract the sum of all the stoppage times from total processing time.

4) For example, we have a total of 480 minutes in one shift and our production rate is 120

jars/minutes, so if we calculate our ideal production, it will be 480 x120.

5) If there is a break of 30minutes then remaining working time is 450 minutes, so now is

the need to subtract the downtimes, in this way we calculate during processing of

complete shift.

6) If we calculated the downtimes of 70 minutes then our remaining working time is 450-70.

7) Now our production will be (450-70) x120.


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Actual

Mixed Fruit Jam (450 g)

Task Unit Observation

Downtime Mins 84

CIP Mins 90

Batch Cooking Time Mins 50

Rework Bottles 412

Break Time Mins 35

Cooler Bottles 2676

Operating Time Mins 191

Downtime loss Bottles 10080

Prod/Shift Bottles 19832

Downtimes

Minor Stoppages

Point Electrical Mechanical Utility Total

Time (min) Time (mins) Time (mins) Time (mins)

Jar Feeders 0 16 0 16

Conveyors 0 0 0 0

Washer 0 0 0 0

Filler 0 0 0 0

Capper 0 8 2 10

Cooling Tunnel 0 7 0 7

Labeller 0 4 0 4

Jar Coding 0 0 0 0

Tray Coding 0 0 0 0

Shrink Wrap 0 0 0 0

Total 0 35 2 37

Major Stoppages


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Point Electrical Mechanical Utility Total

Time (min) Time (mins) Time (mins) Time (mins)

Jar Feeders 0 0 0 0

Conveyors 0 30 0 30

Washer 0 0 0 0

Filler 0 0 17 17

Capper 0 0 0 0

Cooling Tunnel 0 0 0 0

Labeller 0 0 0 0

Jar Coding 0 0 0 0

Tray Coding 0 0 0 0

Shrink Wrap 0 0 0 0

Total 0 30 17 47

7.1.2 Boilers

1) Boilers are necessary for any industry to produce steam for two major purposes, to

produce pressure and heat.

2) For these purposes, in Mitchells, there are two types of boiler i.e. oil/gas boiler and

coal/wood boiler.

3) There are two gas boilers having a maximum capacity of 4 tons/hour each.

4) Coal based boiler is a new one imported from china just two years back, with very high

capacity of 10 tons/hour.

5) In coal boiler, we can achieve a maximum pressure of 10 bars at 182˚C but usual

operating pressure is 7 bars at 173˚C.

6) In boiler, there is a water considered as optimum that is +20, while its has a range of -50

to +50, water level should not be down to +20.

7) Usually the temperature of feed water is 40˚C which is increased by an economizer

(increase temperature of feed water by exhaust gases) to 90˚C just before feeding.

8) The pressure of feed water pump should be more than the pressure in boiler to prevent

back flow.


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9) The pH of boiler water should be between 10.5 to 11.5 to prevent the attack of oxygen

and rust.

10) Maximum TDS of boiler water should be below 3500 ppm. When the pH of exhaust

water (containing exhaust gases of boiler) lows down to 2-3 then change the water or add

caustic soda to increase it pH.

11) Feed water analysis includes the hardness of water and TDS.

12) Boiler water analysis contains the tests for Hardness (CaCO3, MgCO3, phosphates,

sulphates), pH, and TDS.

7.1.3 Water treatment plant

Today we visit the water treatment plant which treat all drain water comes from all production

plants where water is excessively used .When water of production plant is drained out, it consist

of different organic & inorganic material which cause harmful effects on environment and life.

For this purpose Factory management team has established the waste water treatment plant to

prevent this action. This plant is working 24 hours automatically. Whenever the water level of

main tank cross the limit the pump is automatically on and starts feeding to aeration tank.

Plant consists of three major parts.

1) Main tank

2) Aeration tank

3) Clarifier tank

Main Tank:

Waste water of all production plants accumulate in this tank through pipes. There is a

set point in tank, when water accumulates at that point then feeding pump automatically on and

feed the water into the aeration tank and this process continuously.


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Aeration tank:

A compressor is set up near the tank which compress the air and provides that air in

the aeration tank .In this tank, we also provides media ( DAP 5 kg and Urea 15 kg) for the

growth of microorganism like Bacteria . After that process, bacteria growth starts in the presence

of oxygen and fertilizers. Bacteria decompose the organic matter which is present in waste water.

Gradually, water moves to the Clarifier tank.

Clarifier tank:

In this tank, agitator is worked out at 3 rpm through this agitator water moves slowly

due to which sludge is settle down. Clarified water float up and moves out of the tank by small

spaces present on top the tank. This water drained out in a nearly situated canal.

7.1.4 Overall Equipment Effectiveness (OEE)

We learned about OEE and apply on a chocolate molding plant.

OEE consist of three basic aspects which are following

1) Availability %

2) Performance %

3) Quality %

Availability %:

It is the ratio of running time of machine and total available time and multiplies

with100.

Availability% = Running time/Total available time x 100

For example, Total shift time is 480 mints and our planned time is 80 mints (50 mints for CIP

and 30 mints for brake time) and in this way our available time is 420 mints. In available time, if

running time is 365 mints and remaining time is lost due to down time losses then our

availability % is following

Availability% = 365/420 x 100 = 86.90%

Performance %:

It is the ratio of actual production by a machine and a standard production by a

machine and multiplies with 100.


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Performance % = Actual production/Standard production x 100

For example, if standard speed of machine is 122 jars/ mint then standard production in running

time should be

Standard production = 365 x 122 = 44530 jars

In this way, if machine is working at 109 jars /mints instead of 122 jars /mint then our total

production will be

Actual production = 365 x 109 = 39785 jars

Using the formula, we can calculate the performance %

Performance% = 39785/44530 x 100 = 89.34%

Quality%:

It is the ratio of good production to total production multiplies with 100.

Good production:

It is the quantity of products which remains after rework and visual inspection

as original production.

Quality% = Good production/Total production x 100

For example, if our total production is 39785 jars, after rework and visual inspection the

remaining jars is 39112 jars.

Rework = 39785 – 673 = 39112 jars

That jars is our Good product and in this way we calculate the Quality% by using the formula

Quality% = 39112/39785 x 100 = 98.30%

Calculation of OEE = Availability x Performance x Quality

7.1.5 Syrup Section


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Syrups and syrup juice mixtures are prepared by using Pearson’s formula.

Q. Make a 650 kg juice of 40˚Brix from sugar syrup of 72˚Brix and mango pulp of 16˚Brix.

Now solve this as (Brix)

(Required - Pulp) + (Syrup - Required)

(40 – 16) + (72 - 32) = 56

Syrup %age:

= 24/56 x 100 = 42.85

Syrup Required (Qty):

= 42.85/100 x 650 = 278.57 kg

Pulp %age:

= 32/56 x 100 = 57.14

Pulp Required (Qty)

= 57.14/100 x 650 = 371.42 kg

Q # 2: Make a syrup of 80˚Brix from 30 kg sugar.

Syrup = 100/80 x 30 = 37.5 kg

Required Water = 37.5 kg – 30 kg = 7.5 kg

Q # 3: Make 800 kg syrup of 67˚Brix.

Required Sugar = 67/100 x 800 = 536 kg

Required Water = 800 – 536 = 264 kg

7.1.6 Weekly Progress Reports

First Day at Mitchell’s

Our first day at Mitchell’s was 22nd

of June 2015. Human Resource manager (Sheikh Naveed

Ahmed) refers us to our Incharge Mr.Shoaib Awan (Plant operation manager) who took a short

introduction about our studies and residence and call Mr.Waseem (Grocery plant Supervisor)

who visits us whole industry sections which includes:

1) Grocery plant


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2) Confectionary plant

3) Pulping plant

And give us detailed instruction about processing. Then internship letter was issued from HRM

office which contains timing, instructions and schedule of our working days.

Introduction is briefly described above.

1st Week Progress

1) On Monday, we are visited the whole industry Plants & sections.

2) On Tuesday, we learn about the processing of Jam-e-hayat.

3) On Wednesday, We worked on the Sauce line and learn the processing of Chili Garlic

Sauce and asked about the question.

4) On Thursday, Our Incharge has assigned a duty in confectionary plant and we saw whole

processing of MCE (Milk chocolate éclairs) soft candy.

5) On Friday, our task was Quality parameters of Jam -e- hayat and we checked it regularly.

6) On Saturday, We learn about the whole processing of Hard Candy.

2nd

Week Progress

1) On Monday, our Incharge has assigned a duty in Pulping plant where we are worked on

the processing of Chick pea.

2) On Tuesday, our duty was in main lab where we learn and perform the different quality

analysis tests.

3) On Wednesday, we worked on the preserve line /jam line and learn about Golden mist

Marmalade processing and quality parameters.

4) On Thursday, we worked on Variance Analysis and calculate the total production in shift.

5) On Friday, We learn about the processing of lemon squash on the Squash line.

6) On Saturday, Our duty was in Chocolate Molding plant and learns about the processing

of Jubilee.

3rd

Week Progress

1) On Monday, we worked and observe the whole processing, canning & in pack

sterilization of Sag.


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2) On Tuesday, our duty was on preserve line where we observe the processing, filling

speed, capping, coding, labeling, and packaging of Ginger paste.

3) On Wednesday, we worked on processing of Garlic ginger paste and quality parameters.

4) On Thursdays, We perform the different quality analysis tests in main lab.

5) On Friday, our task was in pulping plant where we saw the whole processing and

chemical mixing of mango pulp.

6) On Saturday, our incharge has assigned a duty to check the quality parameters of Mango

pulp.

Conclusion

The production & quality control Department of Mitchell’s Fruit Farms Ltd. seems to be catering

to the needs and wants of the customer & employees very effectively and efficiently. But issues

like decentralized- decision making is still lacking. The control is mostly in the upper levels. But

the good aspect is that they treat their lower levels in a nice manner. Also the production and

quality control department is still going under its initial changes and need time to get settled in

the organization. As the technological advancement, is getting more intense with the passage of

time, the production department & quality control of Mitchell’s Fruit Farms Ltd. is trying its best

to settle the employees within the organization according to this advancement. The practices they

are performing in the organization and its rapid growth shows its effectiveness and the accepting

behavior of their employees shows they want this new change in the environment and want to

grow with the organization. Overall production & quality control department of Mitchell’s is

performing well; it is also providing its employees opportunities for their career development

and for their better future. I conclude

1) I did work in all 4 sections of Mitchells

2) Grocery, jam-e-hayat, orange squash, chick pea

3) Confectionary, soft and hard candy

4) Pulping plant, mango pulp (aseptically filled)

5) Chocolate Moulding Plant (Jubilee)

6) Case studies (OEE, Downtimes, Syrup Preparation)


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7) Maximum products exported

8) Meet international standards

9) Good performance

10) Links country product standards

11) Effective coordination with workers

12) Lack of worker safety implications

13) Management has main focus on quality

Suggestions / Recommendations 1) There are some machines/motors which are not covered, so they should be covered to

reduce accidents.

2) Some powerful motors when on they produce high vibrations due to which nearly present

pipes and other things shakes, which is dangerous.

3) The free friendly environment of workers during working can harm them. Worker’s

concentration should be totally on their work.

4) Washing the machines during filling of product produce splashes which can cause

contamination of food products, it should avoid.


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References

Resource persons

1) Mr. Shoaib Awan (Plant Operation Manager)

2) Mr. M. Idrees

3) Mr. Muhammad Umair Butt (Quality Assurance Manager).

4) Mr. Shoukat Ali (R & D Lab Supervisor)

5) Mr. M. Ashiq (QA. Lab Supervisor)

6) Mr. Zohaib Ayub (Quality Assurance Officer)

7) Mr. Fazal Abbas (Quality Assurance Officer)

8) Mr. Qasim Sikandar ( Microbiologist)

Website

www.mitchells.com.pk

Documents

The Islamia University of Bahawalpur Report Hafeez.pdf · introducing fruit squashes under the brand name of Mitchell's" Kissan". In 1947, as a result of emergence of Pakistan,