TRAINING REPORTAFS 490 (INDUSTRIAL TRAINING)

B.Sc. (Food Technology)

Semester II, 2015-16

by

Mridula Bhandari

(ID NO. 43831)

Department of Food Science and Technology

GB Pant University of Agriculture and Technology

Pantnagar, U.S. Nagar (Uttarakhand)

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ACKNOWLEDGEMENT

The internship opportunity that I had with Parle biscuits Pvt. Ltd. was a great choice for learning and professional development. I consider myself as a very lucky individual as I was provided with an opportunity to be a part of it. I am also grateful for having a chance to meet so many wonderful people and professionals who led me through this internship period.

I am using this opportunity to express my deepest gratitude to the Executive HR Sir – Mr. Jagdish Giri Goswami and Production Manager Sir- Mr. Sanjay Yadav along with others, who in spite of being extraordinarily busy with their duties, took time out to hear, guide and keep me on the correct path and allowed me to carry out my project at their esteemed organization.

I perceive this opportunity as a big milestone in my career development. Hope to continue cooperation with all of you in the future.

Sincerely,

MRIDULA BHANDARI

PANTNAGAR

02/05/2016

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TABLE OF CONTENTS

TITLES PAGE NO.

COMPANY PROFILE 4 BRANDS 5-6 PRODUCT PROFILE 7-8 BISCUIT PRODUCTION PROCESS 9-18 PROCESS FLOW DIAGRAM 19-20 IMPORTANT TIME & TEMPERATURES 21 WRAPPER QUALITY STANDARDS 22 GENERAL DATA 23 FINDINGS AND SUGGESTIONS 24 CONCLUSIONS 25-26 REFERENCES 27

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COMPANY PROFILE

A long time ago, when the British ruled India, a small factory was set up by Mohanlal Dayal Chauhan in the suburbs of Mumbai city, to manufacture sweets and toffees. His dream was to make Parle a symbol of quality, nutrition & great taste. The year was 1929 & the market was dominated by famous international brands that were imported freely. Despite the odds & unequal competition, Parle products survived & succeeded by adhering to high quality & improvising from time to time.

A decade later, in 1939 Parle products began manufacturing biscuits, in addition to sweets & toffees. Its 1st brands include Parle Glucose & Parle Monaco. Many of the Parle biscuits & confectionaries are market leaders in their category & have won acclaim at the monde selection.

Apart from factories in Mumbai and Bangalore, Parle also has factories in Bahadurgarh, Haryana and Neemrana, Rajasthan. These are the largest biscuit and confectionery plants in the country. Additionally, Parle Products also has 10 manufacturing units and 75 manufacturing units on contract.

As of 2012, it had a 35% dominant share of the Indian biscuit market. Parle G is the first Indian FMCG brand to cross the 5000-crore mark in retail sales in a year. Today Parle is a multimillion dollar company.

BRANDS4

Biscuits

Parle-G, Cream biscuits (Orange, Chocolate, Pineapple & Elaichi), 20-20 (Cashew butter & butter), Glucose biscuits, KrackJack, Monaco, Kreams, Golden Arcs, Parle Marie, Milk Shakti, Parle Hide & Seek Bourbon, Parle Hide & Seek Fab, Top, Parle Gold Star, Happy Happy, Simply good, Namkeen Parle magix, Coconut, Cheeslings

Sweet confectionery

Melody, Mango Bite, Poppins, 2 in 1 Eclairs, Mazelo, Kismi Toffee Bar, London Derry, Golgappa, Kaccha Mango Bite

Snacks

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Monaco Smart Chips, Parle's Wafers, Fulltoss, Musst Bites, Parle Namkeens, Parle rusk, Parle Cake, Musst Chips

Latest product are Musst chips (Red chill achar, Classic salty, Sweet & spicy chatni and Aloochatt) hence enjoys strong imagery and appeal amongst consumers.

In SIDCUL Pantnagar plant Parle-G, 20-20 butter cookies & Orange cream biscuits are manufactured.

PRODUCT PROFILE

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Parle biscuits are linked with factors of power and wisdom providing nutrition and strength. Parle biscuits are indeed much more than a tea-time snack, they are considered by many to be an important part of their daily food. Parle can treat you with a bucket of biscuits which are not only satisfying but are also of good and reliable quality. Parle biscuits cater to all tastes from kids to senior citizens. They have found their way into the Indian heart and homes.

Over 76 years, Parle G has been a part of the lives of every Indian. From the snow capped mountains in the north to the sultry towns in the south, from busy cities to laid back villages, Parle G has nourished , strengthened and delighted millions.

It is highly nutritious easy to digest can be preserved for long time. By varying the ingredients and flavors it is possible to produce a variety of biscuits. About 50% of the total biscuit production in our country is of glucose biscuits. It is a highly demandable product.

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1). RAW MATERIAL TESTING

The different raw materials are procurated from dealers, stored in a well-equipped store and tested before their use. The different raw materials used are as follows:

SMP - Highly hygroscopic and reactive so it is placed separately from other materials.

PARLE FLAVOUR MIX - Maturation time = 1 month

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SUGAR - Received in crystalline form, it is ground and then stored in storage tank for further use.

SALT - Highly acceptable for moisture uptake, so special precautions are taken to prevent it from moisture uptake.

ETHYL VANILLIN - Stored dry in original unopened containers at controlled room temperature.

VANILLIN - Stored dry in original unopened containers at controlled room temperature.

CITRIC ACID (MONOHYDRATE) - Kept away from heat and water.

MAIDA - Is stored in storage tank after sieving.

FINAMUL-p - Acts as emulsifier. It helps in blending of RBD palm oil and water.

SODIUM BICARBONATE - Used as a leavening agent. It requires care during handling otherwise it may cause allergy in hands, gas formation in stomach and burning in eyes.

AMMONIUM BICARBONATE - Helps soda in its working. It is also dangerous because it enters in gas form along with it causes the misbalancing of body, unconsciousness, headache, burning in eyes or redness in eyes, skin allergy.To avoid this same precautions are required as in soda handling.

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PROPYLENE GLYCOL - Received in liquid form.

ORANGE OIL CONCENTRATES - Used in cream biscuits as flavoring agent.

SOYA LECITHIN - Used as emulsifier.

SUNSET YELLOW COLOR - Used as coloring agent in kreams orange biscuit.

CONDENSED MILK FLAVOR - Used as flavouring essence

SODIUM METABISULFITE - used as preservative

RBD palm oil - (Refined, Bleached and Deodorized)

PACKING MATERIAL - LDPE, HDPE, Poly olefin shrink film, poly bags, BOPP tapes and coupons.

INVERT SUGAR SYRUP - Pale colored sweetener prepared by the acid hydrolysis / enzymatic hydrolysis of a solution of white refined sugar. Invert syrup contains equal proportions of the invert sugars - glucose and fructose.

The term inverted is derived from the method of measuring the concentration of sugar syrup using a polarimeter. Plane polarized light, when passed through a sample pure sucrose solution, is rotated to the right. As the solution is converted to mix. Of sucrose, fructose &

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glucose, the amount of rotation is reduced until the direction of rotation has changed from right to left.

C12H22O11 + H2O

↓

C6H12O6 + C6H12O6

Hydrolysis is a chemical reaction in which a molecule breaks down by the addition of water.

All inverted sugar syrups are created from hydrolyzing sucrose to glucose and fructose by heating a sucrose solution, then relying on time alone, with the catalytic properties of an acid or enzymes used to speed the reaction. Commercially prepared acid catalyzed solutions are neutralized when the desired level of inversion is reached.

Invert sugar has a lower water activity than that of sucrose, so it provides more powerful preserving qualities to product that use it. The shelf life of partial inverts is approximately 6 months, depending on storage and climatic conditions.

Advantage over sucrose - It has great ability to retain moisture and it can stay liquid for longer duration.

Other functional properties are -

Keeps food products soft and fresh Does not crystallize on storage. Excellent food preservative Provides body cohesiveness Emulsion stabilizer

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Along with all these it provides taste, shine, color to the biscuit, helps in crust formation and also helps to reduce overall cost, as fructose is sweeter than sucrose.

SALT

Table salt is refined salt, which contains about 97% to 99% sodium chloride. It usually contains substances that make it free –flowing such as sodium silicoaluminate or magnesium carbonate.

Table salt has a particle density of 2.165 g/cm, and a bulk density of about 1.154 g / cm3. It improves flavor of the product.

Preserves food due to its water binding ability. Also causes food dehydration by drawing out water from tissues cells.

SKIMMED MILK POWDER

It is made from skimmed milk. The powder form is easy in handling. The composition is -

MILK FAT (MAX) 1% MILK PROTEIN 35% CARBOHYDRATES 51% MINERALS 7% MOISTURE 3.5% CALORIFIC VALUE - 350 kcal/100gm

It is the main source of protein in biscuits. It also provides flavor, color and nutrition to the product. It has binding action. It is especially useful for diet preparations or for use by people on low calorie and high protein diet.

RBD OIL

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RBD is refined, bleached and deodorized palm oil. It is a light yellow liquid and semi – solid at room temperature, melting to a clear yellow liquid on slight heating.

It is used to a short or crumbly texture. It is now known that shortenings work by inhibiting the formation of long protein strands in wheat–based dough. This also provides smoothness and tenderness to the biscuit.

2). MIXING (preparation OF BATCH)

Ingredients SMP Salt Soda Ammonium bicarbonate Finamul-p Condensed milk flavour Maida

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Sugar Sugar syrup Ghee

Process for making dough for Parle G biscuit

Finamul-p, water, sugar syrup, salt, ammonium bicarbonate and soda are mixed. This is then combined with sugar and flour.

SMP and rework is also added. This mixture is then fed into Stefan mixer. After mixing, dough is ready whose temperature is at 30-33◦ C

for cream biscuit and 28-32◦ C for Parle -G glucose biscuit. During mixing in rotator -16◦ C brine solution is circulated in to

prevent the blister formation in the biscuits.

3). Moulding section

After mixing, when the dough has been prepared, its consistency can be controlled in 3 ways:

1. By addition of water2. Controlling rotation of rotator3. Controlling temperature

Prepared dough is fed into the hopper by dough trolley from where it passes to the dough cushion which pushes the dough to the shutter.

With the help of the dough cutter it is cut into small pieces. It passes through the metal detector to avoid any ferrous and non ferrous material.

NOTE: Critical limit of metal detector:

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Ferrous: 1.5mm Non ferrous: 2.0mm Non-ferrous (Sulphur): 2.5mm

If any metal is present, then the conveyor belt stops and that amount of dough passes through a separate metal detector and if no metal is present, it passes easily on the dough conveyor belt.

All the air present in dough is removed by forcing roll which prevents the cracking of biscuits.

Now dough passes to die roll that provides shape to the unbaked biscuits.

With the help of rubber roll, moulded unbaked biscuit are transferred to rotary belt.

The rotation of rubber roll affects the dimension of biscuits.

Now the biscuits move to the oven for baking.

4). BAKING

It has mainly 3 zones:

1. PUFFING ZONE2. BAKING ZONE3. COLORING ZONE

The length of puffing zone is around 30%, baking zone is 45% and that of coloring zone is around 25% of the length of oven.

The oven is divided into 10 zones:

Starting zones i.e. 1-3 are the puffing zone in this the moisture content of biscuit is reduced.

Baking zones i.e. 4-8 are also known as CCP zone (critical control point ). In these zone biscuit get baked and enlarged due to leavening

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of CO2 and ammonia. After baking process the moisture content is reduced to 2-4 %.

Lastly zones i.e. 9-10 impart color to the biscuit.

The temperature profile of oven play important role in the appearance of biscuit. To avoid the sticking of biscuit the wire bound is preheated. The temperature of top burners is 10 °C higher than bottom burners. The temperature of initial zones is kept low to prevent hardening and for easy release of ammonia vapors.

Oven has 333 burners. The source of heat used is LPG, it is injected along with air under high pressure to produce heat. The combustion process is spark ignition process. The heat produced in this process transfers to biscuit through all 3 modes of heat transfer: conduction, convection and radiation. The temperature of oven is control according to die RPM.

NOTE : The critical limit temperature of oven

Critical limit: 220 °C - 330 °C Action limit: 230 °C – 320° C Target limit: 240 °C - 310 °C

Exhausts are set which control the heat generation of different zones of the oven. Exhaust clamps has 0-9 positions. At 1st position small heat is transferred and at 10th position whole heat is released from the oven.

MOISTURE (LCGC Moisture meter)

Critical limit: 2.4% Action limit: 2% Target limit: 1.6 – 1.8%

5). COOLING SECTION

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Natural air cooling is preferred for the product to avoid the cracking of biscuit. Approx 350m long conveyor is used for the cooling purpose, the temperature of the biscuit when it comes out from the oven is near about 90 °C – 100 °C, which is reduced to 45 °C.

If rapid cooling is allowed, it removes moisture only from the crust; crump still has moisture that may cause rancidity.

Cooling conveyor belt is divided into 3 tiers according to their length:

First tier - 270m Second tier - 150m Third tier - 30m

The conveyor belt is PVC coated cotton belt. Its width is 60 inches and thickness is 1.5mm. Tensioning rollers help in straightening of the belt. If belt is loose, biscuits are drawn in sides and hopper. The proper speed of conveyor is essential for the proper cooling of the biscuits.

NOTE: The cooling time should be more than double the baking time.

6). PACKAGING SECTIONWhen biscuits are properly cooled they are transferred to the dribble table after passing to a metal detector. Then, biscuit is transferred on a woolen conveyor which is used to avoid breaking of biscuits and to make proper gripping with biscuit.

Then they pass through wire brush which separates them and passes them as single biscuit on the stacker table. The gap between wire brush and stacker table is according to the thickness of baked biscuit.

Various multi pack package machine are available with stacker table. The length of stacker table is according to the target. Stacker lines are distributed according to the availability of the machines.

Stacker lines move to auto feeder, from where they come in in-liner. Biscuits now move to the wrapping section, where horizontal feeding

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and auto wrapping machine helps in covering of wrapping roll on the stack via moving over former box. There are 2 gripping balls and 2 long seal heaters which provide long seal to the packet. Long seal packets are cross sealed and cut into individual packs by cutter. Now a complete packet is obtained with proper long seal, cross seal and gathering. This process is controlled automatically.

Cream biscuit directly enters in filling section from the stacker table. Cream is filled in between 2 biscuits and forms a sandwich machine. Then it goes for packing. Cream biscuits wrapping has vertical feeding auto wrapping machine. Plant consists of fully automatic sealing machine, taping machine and multi pack machine. BOPP is mainly used as primary packaging material and cardboard used as secondary packaging material.

Process Flow Diagram

ADDITION OF RAW MATERIALS

The main base component maida, along with other

materials are added which provide various properties.

↓

MIXING

Raw material is added in fixed quantity.

↓

DOUGH HOPPER

Prepared dough is stored in it.

↓ COOLING CONVEYOR It brings the temperature of biscuit upto 45 °C

↓

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PACKING Protects the product

↓

SEALING AND TAPING It is done automatically.

↓

DISPATCH Distributed to the market.

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NOTE - AT EVERY STEP THERE ARE DIFFERENT PARAMETERS TO CHECK THAT THE PRODUCT AFTER EACH STEP IS IN RIGHT SHAPE, TEXTURE, SIZE AS

IT IS MENTIONED OR REQUIRED AS PER PARLE STANDARDS.

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IMPORTANT TIME AND TEMPERATURES:

BAKING TIME - 3min 27sec

FILLING ROOM TEMPERATURE - 26.7 °C

MIXING ROOM TEMPERATURE – 28.2 °C

RBD TEMPERATURE - 40 °C

INVERT SYRUP - 38 °C

WATER - 26 °C

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WRAPPER QUALITY STANDARDS

PG-28gm: LENGTH -106 mm, WIDTH -172mm, WEIGHT -0.593g, GSM – 32.54

PG – 72gm: LENGTH – 106 mm, WIDTH – 306 mm, WEIGHT – 1.055gm, GSM

PG-56gm: LENGTH – 106 mm, WIDTH – 306mm, WEIGHT – 0.886 gm, GSM – 32.54

PG-300 gm: LENGTH -106mm,WIDTH – 318 mm, WEIGHT -0.763gm, GSM- 22.625

OUTER WRAPPER: LENGTH -294mm, WIDTH – 306mm, WEIGHT -3.518gm, GSM-39.10

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GENERAL DATA

Die has 384 cups

Oven has 333 burners

Unbaked biscuit (16 biscuit) - 91.2 gm

Weight of unbaked biscuit - 5.7gm

Weight of baked biscuit - 4.7gm

Length of biscuit - 55 mm

Width of biscuit (Parle –G) - 34mm

Width of biscuit (cream) - 32mm

Height of 16 biscuit (Parle- G) - 114mm

Height of 16 biscuit (cream) - 90mm

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FINDINGS AND SUGGESTIONS

FINDINGS

STRENGTHS

Low product price Sizeable market share Variety of products Deep and effective coverage Largest distribution system Better understanding of consumer needs

WEAKNESS Depends on Parle G Lacking schemes Replacement of damaged stock Packing of biscuits Fake brands like Parel G and Parle Jee extracting market share.

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SUGGESTIONS

- With increasing cost of raw materials, the price of Parle’s flagship product should remain the same in coming future while increasing the prices of other high end variants like Hide & Seek, Milano and Bourbourn.

- High end products can absorb the increased production cost. This will help to cater existing market price without price change.

- Dealing with the weaknesses mentioned above in an impactful manner.

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Conclusion

Largest selling biscuit brand Healthy ingredients Consumed by all age groups Good distribution channel Excellent marketing strategy

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REFERENCES

1. Duncan Manley, Biscuit, cracker and cookie recipe for the food industry, Woodhead Publishing Limited, 2001

2. Duncan Manley, Manley’s technology of Biscuits, Crackers and Cookies, Woodhead Publishing Limited 1983

3. https://en.wikipedia.org/wiki/Parle_Products

4. http://www.parleproducts.com/

5. Parle-G becomes India’s first homegrown 5K crore FMCG brandhttp://articles.economictimes.indiatimes.com/2013-02-13/news/37079254_1_parle-g-parle-products-glucose-biscuit-brand

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