A

Training Report
On

PROCESS STUDY & MANUFACTURING OF

BISCUITS

BUNTY FOOD PRODUCTS (I) PVT. LTD.

AMBERNATH
Submitted by :Gaikwad Pratik Subhash
B.Tech (FOOD Tech.)
IVth Year
Reg. No. BED09FT09B

ACKNOWLEDGMENT:-

I Thank The Almighty for Providing Me Strength to Finish My Job.

I feel deep senses of gratitude from the core my heart to Mr. Pathak
Sir, H.R., Bunty Foods Pvt. Ltd. For guidance , extensive helps
providing facilities , criticsadmiring
My good job & motivation
to get the job done.
I express my sincere appreciation to Mr. Pathak Sir & Managing
Director Mr. Vinod Jasnani for giving me there valuable time. I am also
grateful to other staff members
& workers.
My sincere thanks to friends & all these who helped me for their
friendly
Company.
Ambernath
2013

GAIKWAD PRATIK SUBHASH

B.Tech (Food Tech)

INTRODUCTION:Bunty food product is working from 1991 in Ambernth (E) & making Biscuits like Parle
G & Exporting it too. It has 2 plants one at the bottom & the Second one at the top.
There are approximate 600 workers working in the company including staff.
There are total 160 machine which consist of 130 packing machine & 30 others. Each
Machine has 8 workers to operate it. Their main objective is to maintain the best
hygiene level & Provide the best quality product to the customers. They have separate
room for wastages.

There are total 8 Department thy are:1.Wages Department

2.Office
3. 5s
4. Laboratory
5. Maintenance
6. Store
7. Reception
8. House Keeping
There are 2 shifts i.e. from morning 7.30 am to evening 7.30pm which consist of women

THE CUSTOMER CONFIDENCE:The Parle name conjures up found memories across the length &
breadth of the country. After all, since 1929, the people of India have
been growing up on Parle
Biscuit & Sweets.
Today I the brads have found their way into the hearts & homes of
people all-over India & abroad. Parle biscuits & confectionaries
continue to spread happiness & joy
Among people of all
the ages.
The consumer is the focus of all activities at Parle. Maximizing value
to consumers and forging enduring customer relationship are the
core endeavors at Parle.
Our efforts are driven towards maximizing customer satisfaction &
this is in synergy with our quality pledge. Parle Product Limited will
strive to provide consistently nutritious & quality food products to
meet consumers satisfaction by using Quality materials & by
adopting appropriate processes. To facilitate the above we will strive
to continuously train our employees & to provide them an open &

PROCESS FLOW DIAGRAM:Start

Raw
Materi
al

Pannin
g Table

Mouldin
g

Dough
Hoppe
r

Oven

Cooling
Convey
or

Dribbl
e
Board

Sealing
&
Taping

Packin
g

Stackin
g Table

Stora
ge

Distributi
on

Mixing

INGRADIENTS USED IN
PARLE-G:Name Of

% By Mass

Ingredients

Maida

110.0

Sugar

33.0

RBD

20.9

Sugar Syrup
Salt

11.0
180gm

Skim Milk Powder

780gm

Sodium Bi-Carbonate

350gm

Sodium Meta Bisulphate

(S.M.B.S.)

10-15gm

Finamul

60ml

Water

Variable

Ammonium Bi- Carbonate

500 to 1000gm

(ABC)
Beside these 170 ml of Parle Flavor is added to recipe
Amount Of Vanaspati Ghee may vey according to hardness of madia used.

ROLE OF INGREDIENTS :Flour (Maida):Wheat flour determines the finished quality of most bakery products. Among
the reasons for strong influence of flour are:1. Unique protein in wheat given most bakery products a characteristics
highly expanded structure.
2. wheat flour is present in larger proportion than any other ingredients. Its
the basic ingredient added in the largest share in the preparation of biscuit
dough. It should make dough having more extensibility but less spring
(resistance) than bread dough. Dough pieces should retain their size &
shape after being stamped out. Maida is hydrated & kneaded these two
proteins from gluten is a complex mixture of nitrogenous compounds that
gives wheat flour dough its cohesive & elastic property gluten entraps
carbon dioxide released by chemical leavening agents & air gets
incorporated during mixing. This results in unique expansion of dough
hence end product is light smooth textured & delightful.

Sugar:Sugar is responsible for sweetness of biscuits. Its added in ground from.

Sugar molecules breaks down to glucose & thus builds high glucose level
in biscuits. Sugar also contribute to tenderness

FAT (SHORTENING):Shortening is a word used to describe fats, oils & various processed of fats &
oils that are used as ingredients in dough & better they lubricate the internal
structure of intermediate to allow grater expansion during proofing & baking
& they make the texture of finished products tender, modify the visual &
tactile texture of the crust in desirable ways.
Shortening of the gluten strands is the major function of fat but also gives
smoothness & tenderness to the biscuit. They supply calories & essential fats
acid; acts as a vitamin carrier & increase the palatability of the product. Its
main source of fats in biscuits. Fats contribute to tenderness flavor, colure &
texture of biscuits. These acts as shortening in preparation of cohesive gluten
structure. It prevents hardening of biscuits during & after baking.

SUGAR SYRUP:A Fraction of sugar is added in liquid form. This helps in breaking down of
sugar molecules to glucose. Sugar in syrup form readily undergoes blowing
reaction at high temperatures, which is responsible for colure& flavor of
biscuits.

SALT:-

SKIM MILK POWDER:Skim Milk Powder is used in powder form in biscuits for ease of handling.
Milk is the main source of protein in biscuits. It also adds fats, sugar,
vitamins & some enzymes to biscuits.

SODIUM BI-CARBONATE:Sodium Bi-Carbonate is used as leavening agents. Leavening is the

process of handling the area of dough by creating in them small bubbles
of gas (CO).
Sodium Bi-Carbonate (NaHco) + Ammonia (NH) ---- NHHCO
Heat
NHHCO --- NH + CO + HO
It also imparts colure & control h.

AMMONIUM BI-CARBONATE (ABC):Ammonium escapes at high temperature during baking.

S.M.B.S.:-

FINAMUL:Its an emulsifier used for binding of fat & water

molecules.
Its added in very small quantity to mix along with
ghee.

WATER:It works as a solvent in dough mixture. Water used in

biscuits is well
filtered by reverse osmosis process. Moisture content in
final form
of biscuit in just 2-3/0 which is not enough for
microbial growth.

FLAVOR:-

RAW MATERIAL DESCRIPTION:VANASPATI:The material shall be clear in appearance on melting & free from sediments,
suspended & other foreign matters. It shall have characteristics odor & taste
& shall be from foreign odor & taste.
1. F.F.A.(as oleic acid)

: o.10;0max

2. Iodine value

50-55

3. Peroxide value

: 1.25menu/ kg. Max

4. Melting point &

sometimes higher

: Range from 34-37c

5. Tanker filling Temp.

: 45c (summer)

6. Odor

Completely odorless with pleasant

7. Texture

Creamy without any grains or lumps

8. Purity

Pure without any extraneous matters

Taste

WHEAT FLOUR:1. Moisture, % Max

2. Gluten, % Max

SOFT

HARD

13.0

13.0

7.5-8.5

9-11

0.05

0.05

4. Water Absorption
Capacity, % min

55

55

5. Uric Acid M9/100

Gm. Max

10

10

3. Acid Insoluble Ash %

By Mass

6. Granularity Should be Pass Through 180 Micron Sieve

PRODUCATION PROCESS
(PARLE-G):Raw material testing
Mixing
Moulding
Baking
Cooling
Packing

EXPLANATION:Raw material testing :The first stage of the process is the inspection of raw material, as the
company is the food-processing unit. Therefore it does not make any sort of

MIXING:The solid raw material are sent to the mixer on the second floor from the
ground floor through the suction unit. This unit has very high capacity of
sucking the material. It can suck 50 kg of material at a time. This unit is
totally computerized. Then the material are mixed with the oil in this mixer to
form dough. It is very big & has capacity of mixing 500 kg of raw material at
a time. The level is maintained through the computers.

MOULDING:In this stage the biscuit are given the shape. The Moulding roller can give
shape to 360 biscuits at a time. In one minute 10,000 biscuits are given
shape. Previously because of joint conveyer belt the shapes of 10-15 biscuits
used to get spoilt which leads to damage of 500 biscuits a day costing a loss
of Rs 132 a day amounting to Rs 3,960 a month & Rs 47,520 a year.
But, now the company has imported stretchable conveyer belts from
Japan for all four ovens. These belts transfer biscuits from one belt to another
in a better way so that not even a single biscuits shape is spoiled.

BAKING:This is the actual formation of biscuit. This is the stage where biscuits are
baked in an oven. The company has the biggest oven in Asia. It is 260 feet
long & has 215 burners fitted in it. The temperature in the oven varies as the
biscuits pass through the burner. The temperature is managed by computers

COOLING:After the biscuit are baked they are passed through conveyer belts on the
first floor. It takes 5 minutes to reach the packing machine in order to pack.
During this time span of 5 minutes they are passed in natural air & are
ultimately cooled. If hot biscuits are packed then they will lose their
crispness.

PACKING:There are 6 packing machine around the belt & all the machine can be
computerized adjusted to the requirement of the biscuits to be packed. There
are 3 types of packing each of 50gms. & 250gms. Also are respectively 2
machines for each type of packing.
Previously, due to conveyor belt, sometimes, there was an interruption in
the process, by the wrapper, which used to stick or biscuit used to stuck in
between, but now the process are well managed the belt. There are 25
workers sitting beside the belt to pick up the packets passing through the belt
& pack them in the polythene bags in a range of24 packets each of 50gms,
12 packets each of 100gms,
4 packets each of 250gms.
After packing it in bags they pass it through another conveyor belt
moving on the other side. Which thereafter are sealed & packed in cartoons.

PARLE QUALITY
SYSTEM:Hygiene is the precursor of every process at Parle. From
husking the wheat & melting, the sugar to delivering the
final products to the super market & store shelves
nationwide care is taken at every to ensure the best
product with long lasting freshness. Every batch of
biscuits & confectionery are thoroughly checked by the
expert staff, using the most modern equipments hence
ensuring the same perfect quality across the nation &
abroad All Parle products are manufactured under the
most hygienic conditions. Great care is exercised in the
selection & quality control of raw materials, packing
material & rigid quality standards are ensured at every
stages of the manufacturing process.

HACCP:Hazard Analysis & Critical Control Point is

systematic preventive approach to food safety &
pharmaceutical safety that addresses Physical,
Chemical & Biological Hazards as a mean of
prevention rather than finished products
inspection. HACCP is used in the food industry to
identify potential food safety hazard.
The seven HACCP Principal are included in the
international system ISO 22000. this standards is
a complete food safety management system
incorporating the elements of prerequisite
programmers for food safety, HACCP & quality
management system which together form an

HR TECHNIQUES ADOPTED
AT PARLE: 5S
KAIZENS
SQS
TQM

5S:1S:- SEIRI
2S:- SEITION
3S:- SEISO
4S:- SEIKETSU
5S:- SHITSUKE

KAIZENS:Kaizen, a Japanese term that

basically translates to Continuous
improvement or change to
become good. Kaizen is aimed at
producing more & more value with
less & less wastes (Higher
efficiency), attaining better
working environment, &

TQM:Total Quality Management (TQM) is a business

management strategy aimed at embedding
awareness of quality in all organizational process.
Total: Involving the entire organization, supply
chain, & / or products life cycle.
Quality: With its usual definitions, with all its
complexities.
Management: The system of managing with
steps like Plan, Organize, Control, Lead Staff,
provisioning & organizing.

POKA-YOKE:Poke Yoke is a Japanese

Technique which means
mistake proof system.
Yokeru means to avoid &
Poka
means inadvertent errors.
Poka

% Of Workers who Think

Kaizens
Has Reduced The
Wastage:3
%

0
%

97%

According To Workers Which Among

The Following
Factors Are Main
Cause Of Wastage:-

17%

20%
3
%

60%

OPERATOR
AWAY
MACHINE
PROBLEM
DELAY IN
MATERIAL
POWER CUT

Deptt Wise Result Of PQS

Quiz:21
%

26%

18%

17%
18%

PERSONNEL
ACCOUNTS
IT BRACH
CHIP PLANT
ENG. DEPTT

Also a PQS test was taken of workers & their average

score was 75.86%