Work and Training place

Name
(Innovative biscuit pvt Ltd shakhupura)

Report writing:
Summary:
I started my internship from

24 March , 2015

in innovative Biscuits

Pvt Ltd Shakhupura. My main focus is on Quality Assurance Department.

Right from the start,

First day my supervisor assigned me to work in an Old

Hall.

Products:
Line 1:
Goodies (lemon flavor)
Goodies (plains ,eggs and milk flavor)
Snoper

Line 3:
Xtras
Choco n Chip
Peanut

Processing Steps for Goodies:

Mixer

Hopper feeding
Dough feed conveyer
Metal detector
Die
Knife cutter (cutting)
Oven (puffing,baking,colouring)
Cooling conveyer
Packing machine
Boxes
Carton
Dispatch (finished goods)
Market
consumer

Mixing:
In the mixing section all the ingredients are mixed to make a dough. Mixer
is used for mixing, after mixing products transferred to hopper.

Feeding Hopper:
It is used to transfer the material from the batch or conveyer then material
transferred to stacker.

Feeding conveyer:
It transfer the material in to the dye.

Knife cutter:
It cuts the biscuits and give the specific shape. It cuts the biscuits up to
the ranging of 118-112 cuts/min.

Oven Zone:
It consists of 3 zones.

1st Zone (Puffing):

In this zone puffing of the material occurred.

2nd Zone (Baking):

This is a baking zone the top side temperature of the oven is 195C and
bottom temperature of the oven is 178C.

3rd Zone (colorings):

In this zone usually a color change. It give color to the final product.

Cooling:
Material goes on conveyer belt at 37C for cooling.

Packaging:
Types:
Half Roll (H/R)
Tickey pack (T/P)
Half Roll packaging:
Primary packaging:
(10 biscuits in one pack).

Secondary packaging:
(6 packs in one box).

Tertiary packaging:
(24 box in one carton).

Tickey pack packaging:

Primary packaging:
(3 biscuits in one pack).

Secondary packaging:
(24 pack in one box).

Tertiary packaging:
(18 boxes in 1 carton).

Assignments:

1st assignment:
To check the production line or give reason for wastages?

Reasons:
Having gap or UN equal distribution of heating.
Low weight
Effect of temperature, flour, gluten or other ingredients.

2nd Assignment:
To find the baking loss?

Baking loss % :
Goodies baking loss is 15%
Xtras baking loss is 17%
Standard is 16%
Baking time= 8 min 20 second.
Oven to stacker timing=8 min 25 second.

Reasons of wastage:

Breakage of biscuits
Dough wastage
Temperature change
Weight variation
Shape variation
Over baked biscuits
Eye mark not in proper place
Air in packet
Package corner shrinked
More retention time

 If any problem is found then biscuit is rejected and according to

situation it is moved forward to mixing section for recycling or may be
wasted if not meeting the recycling criteria.

Line 3:
Processing steps for Choco n chip:

Mixer
Hopper
Dough feed conveyer
Metal detector
Die (molding)
Conveyer belt
Wire cut
Glazing
Swivel panel
Oven (direct, indirect)
Cooling conveyer
Stacking conveyer
Packing conveyer
Packing machine
Boxes
Carton
Dispatch (finished goods)
Market
consumer
16 lines on conveyer belt.

Temperature:

1st zone:
Top temperature=48C
Bottom temperature=100C

2nd zone:

240C

3rd zone:
225C

Gross weight:
480g

Ingredients:

Wheat
Flour
Hydrogenated vegetable oil
Chocolate chips (sugar, cocoa, full cream milk powder
Cocoa
Butter and soya lecithin
Raising agents (sodium bicarbonate and ammonium bi carbonate)
Salt
Artificial flavor
Permissible food color

Choco n chip errors:

Variation in shape
Weight
Oven (color change)
Broken biscuits
Double biscuits
One batch time is 45 min/1hr
In 1hr broken biscuits weight=1.6%
In 1hr double biscuits weight=2.8%

3rd Assignment:
Find the Broken and double biscuits weight in 1hr?

Broken biscuits weight in 1hr:

Double biscuits weight = 6.571kg
One batch weight = 267kg
Moisture loss = 16%
1 batch time is 45 min/1hr

267-16% = 1224.28
Formula = wastage/production in 1hr
6.57/224.28*