INDUSTRIAL TRAINING REPORT

AT

BRITANNIA INDUSTRIES LIMITED 33, Lawrence Road, New Delhi-35

ON

MANUFACTURING OF BRITANNIA BISCUITS

SUBMITTED BY:

CONTENTS

S.N.

PARTICULARS PAGE NO.

A. BRITANNIA HISTORYQUALITY POLICIESBRITANNIA PRODUCTSPROCESS DESCRIPTION.BISCUIT CLASSIFICATIONRAW MATERIALS AND THEIR ROLEMANUFACTURING PROCESSQUALITY ANALYSISCONCLUSION.

A.BRITANNIA HISTORY

The story of one of India's favorite brands reads almost like a fairy tale. Once upon a time, in 1892 to be precise, a biscuit company was started in a nondescript house in Calcutta (now Kolkata) with an initial investment of Rs. 295. The company we all know as Britannia today.The beginnings might have been humble-the dreams were anything but. By 1910, with the advent of electricity, Britannia mechanized its operations, and in 1921, it became the first company east of the Suez Canal to use imported gas ovens. Britannia's business was flourishing. But, more importantly, Britannia was acquiring a reputation for quality and value. As a result, during the tragic World War II, the Government reposed its trust in Britannia by contracting it to supply large quantities of "service biscuits" to the armed forces.

As time moved on, the biscuit market continued to grow… and Britannia grewalong with it. In 1975, the Britannia Biscuit Company took over the distribution ofbiscuits from Parry's who till now distributed Britannia biscuits in India. In thesubsequent public issue of 1978, Indian shareholding crossed 60%, firmlyestablishing the Indianness of the firm. The following year, Britannia BiscuitCompany was re-christened Britannia Industries Limited (BIL). Four years later in1983, it crossed the Rs. 100 crores revenue mark.

On the operations front, the company was making equally dynamic strides. In1992, it celebrated its Platinum Jubilee. In 1997, the company unveiled its newcorporate identity - "Eat Healthy, Think Better" - and made its first foray into thedairy products market. In 1999, the "Britannia Khao, World Cup Jao" promotionfurther fortified the affinity consumers had with 'Brand Britannia'.

Britannia strode into the 21st Century as one of India's biggest brands and the preeminent food brand of the country. It was equally recognized for its innovativeapproach to products and marketing: the Lagaan Match was voted India's mostsuccessful promotional activity of the year 2001 while the delicious Britannia 50-50 Maska-Chaska became India's most successful product launch. In 2002,Britannia's New Business Division formed a joint venture with Fonterra, the world's second largest Dairy Company, and Britannia New Zealand Foods Pvt. Ltd. was born. In recognition of its vision and accelerating graph, Forbes Global rated Britannia 'One amongst the Top 200 Small Companies of the World', and The Economic Times pegged Britannia India's 2nd Most Trusted Brand.

Today, more than a century after those tentative first steps, Britannia's fairy tale is not only going strong but blazing new standards, and that miniscule initialinvestment has grown by leaps and bounds to crores of rupees in wealth forBritannia's shareholders. The company's offerings are spread across the spectrum with products ranging from the healthy and economical Tiger biscuits to the more lifestyle-oriented Milkman Cheese. Having succeeded in garnering the trust of almost one-third of India's one billion population and a strong management at the helm means Britannia will continue to dream big on its path of innovation and quality. And millions of consumers will savour the results, happily ever after.

MILESTONES OF BRITANNIA

1892 • The Genesis - Britannia established with an investment of Rs. 295 in Kolkata.

1910 • Advent of electricity sees operations mechanized.

1921 • Imported machinery introduced; Britannia becomes the first company East of the Suez to use gas ovens

1939 - 44

• Sales rise exponentially to Rs.16,27,202 in 1939

• During 1944 sales ramp up by more than eight times to reach Rs.1.36 crore

1975 • Britannia Biscuit Company takes over biscuit distribution from Parry's

1978 • Public issue - Indian shareholding crosses 60%

1979 • Re-christened Britannia Industries Ltd. (BIL)

1983 Sales cross Rs.100 crore

1989 • The Executive Office relocated to Bangalore

1992 • BIL celebrates its Platinum Jubilee

1993 • Wadia Group acquires stake in ABIL, UK and becomes an equal partner with Groupe Danone in BIL

1994 • Volumes cross 1,00,000 tons of biscuits

1997 • Re-birth - new corporate identity 'Eat Healthy, Think Better' leads to new mission: 'Make every third Indian a Britannia consumer'

• BIL enters the dairy products market

1999 • "Britannia Khao World Cup Jao" - a major success! Profit up by 37%

2000 • Forbes Global Ranking - Britannia among Top 300 small companies

2001 • BIL ranked one of India's biggest brands • No.1 food brand of the country • Britannia Lagaan Match: India's most successful promotional activity of the year

• Maska Chaska: India's most successful FMCG launch

2002 • BIL launches joint venture with Fonterra, the world's second largest dairy company • Britannia New Zealand Foods Pvt. Ltd. is born • Rated as 'One amongst the Top 200 Small Companies of the World' by Forbes Global • Economic Times ranks BIL India's 2nd Most Trusted Brand

• Pure Magic -Winner of the Worldstar, Asiastar and Indiastar award for packaging

2003 • 'Treat Duet'- most successful launch of the year

• Britannia Khao World Cup Jao rocks the consumer lives yet again

2004 • Britannia accorded the status of being a 'Superbrand' • Volumes cross 3,00,000 tons of biscuits

• Good Day adds a new variant - Choconut - in its range

2005 • Re-birth of Tiger - 'Swasth Khao, Tiger Ban Jao' becomes the popular chant!

• Britannia launched 'Greetings' range of premium assorted gift packs • The new plant in Uttaranchal, commissioned ahead of schedule.

• The launch of yet another exciting snacking option - Britannia 50-50 Pepper Chakkar

2007 • Britannia industries formed a joint venture with the Khimji Ramdas Group and acquired a 70 percent beneficial state in the Dubai-based Strategic Foods International Co. LLC and 65.4% in the Oman-based Al Sallan Food Industries Co. SAOG.

2008 • Britannia launched Iron fortified 'Tiger Banana' biscuits, 'Good Day Classic Cookies', Low Fat Dahi and renovated 'MarieGold'.

OFFICES OF BRITANNIA

Registered Office5/1/A Hungerford Street,Kolkata - 700 017West BengalPh: 033 - 2287 0505 / 2287 2439 / 2287 2057Fax: 033 - 2287 2501

Executive OfficeBritannia Gardens,Airport Road (old), VimanapuraBangalore - 560 017Ph: 080 - 3940 0080Fax: 080 - 2526 3265 / 2526 6063

Research and Development191, MTH Road, Padi,Chennai - 600 050Tamil NaduPh: 044 - 6614 8083Fax: 044 - 2625 8563

Mumbai OfficeNeville House, 1st FloorCurrimbhoy Road, Ballard Estate,Mumbai - 400 001MaharashtraPh: 022 - 2261 8071Fax: 022 - 2262 6657

Kolkata15, Taratola Road,Kolkata - 700 088West BengalPh: 033 - 3048 8100 / 3048 8071Fax: 033 - 2401 4456 / 2401 4451

ChennaiM T H Road, Padi,Chennai - 600 050Tamil NaduPh: 044 - 3021 6000 / 3021 6001 / 3021 6002Fax: 044 - 2625 8568 / 2625 4872

MumbaiReay Road (East), Mazagaon,Mumbai - 400 010MaharashtraPh: 022 - 6615 6240 / 6615 6245Fax: 022 - 6615 6249 / 6615 6239

Delhi33, Lawrence Road,New Delhi - 110 035Ph: 011 - 3078 8000Fax: 011 - 2718 3499

UttaranchalPlot No.1, Sector – 1Integrated Industrial EstateRudrapur, PantnagarUdham Singh Nagar Dist.Uttaranchal – 263 153.Ph : 09219418114/115/126Fax: 05944 - 250 202

HISTORY OF BISCUIT.

Sweet or salty. Soft or crunchy. Simple or exotic. Everybody loves munching on biscuits, but do they know how biscuits began?

The history of biscuits can be traced back to a recipe created by the Roman chef Apicius, in which "a thick paste of fine wheat flour was boiled and spread out on a plate. When it had dried and hardened it was cut up and then fried until crisp, then served with honey and pepper."

The word 'Biscuit' is derived from the Latin words 'Bis' (meaning 'twice') and 'Coctus' (meaning cooked or baked). The word 'Biscotti' is also the generic term for cookies in Italian. Back then, biscuits were unleavened, hard and thin wafers which, because of their low water content, were ideal food to store.

As people started to explore the globe, biscuits became the ideal traveling food since they stayed fresh for long periods. The seafaring age, thus, witnessed the boom of biscuits when these were sealed in airtight containers to last for months at a time. Hard track biscuits (earliest version of the biscotti and present-day crackers) were part of the staple diet of English and American sailors for many centuries. In fact, the countries which led this seafaring charge, such as those in Western Europe, are the ones where biscuits are most popular even today. Biscotti is said to have been a favourite of Christopher Columbus who discovered America!

Making good biscuits is quite an art, and history bears testimony to that. During the 17th and 18th Centuries in Europe, baking was a carefully controlled profession, managed through a series of 'guilds' or professional associations. To become a baker, one had to complete

years of apprenticeship - working through the ranks of apprentice, journeyman, and finally master baker. Not only this, the amount and quality of biscuits baked were also carefully monitored.

The English, Scotch and Dutch immigrants originally brought the first cookies to the United States and they were called teacakes. They were often flavored with nothing more than the finest butter, sometimes with the addition of a few drops of rose water. Cookies in America were also called by such names as "jumbles", "plunkets" and "cry babies".

As technology improved during the Industrial Revolution in the 19th century, the price of sugar and flour dropped. Chemical leavening agents, such as baking soda, became available and a profusion of cookie recipes occurred. This led to the development of manufactured cookies.

Interestingly, as time has passed and despite more varieties becoming available, the essential ingredients of biscuits haven't changed - like 'soft' wheat flour (which contains less protein than the flour used to bake bread) sugar, and fats, such as butter and oil. Today, though they are known by different names the world over, people agree on one thing - nothing beats the biscuit!

Some interesting facts on the origin of other forms of biscuits:The recipe for oval shaped cookies (that are also known as boudoir biscuits, sponge biscuits, sponge fingers, Naples biscuits and Savoy biscuits) has changed little in 900 years and dates back to the house of Savoy in the 11th century France. Peter the Great of Russia seems to have enjoyed an oval-shaped cookie called "lady fingers" when visiting Louis XV of France.

The macaroon - a small round cookie with crisp crust and a soft interior - seems to have originated in an Italian monastery in 1792 during the French Revolution.

SPRING-uhr-lee, have been traditional Christmas cookies in Austria and Bavaria for centuries. They are made from a simple egg, flour and sugar dough and are usually rectangular in shape. These cookies are made with a leavening agent called ammonium carbonate and baking ammonia.

The inspiration for fortune cookies dates back to the 12th and 13th Centuries, when Chinese soldiers slipped rice paper messages into moon cakes to help co-ordinate their defense against Mongolian invaders.

The Origin of 'Eat Healthy Think Better'

Britannia -the 'biscuit' leader with a history-has withstood the tests of time. Part of the reason for its success has been its ability to resonate with the changes in consumer needs-needs that have varied significantly across its 100+ year epoch. With consumer democracy reaching new levels, the one common thread to emerge in recent times has been the shift in lifestyles and a corresponding awareness of health. People are increasingly becoming conscious of dietary care and its correlation to wellness and matching the new pace to their lives with improved nutritional and dietary habits. This new awareness has seen consumers seeking foods that complement their lifestyles while offering convenience, variety and economy, over and above health and nutrition.

Britannia saw the writing on the wall. Its "Swasth Khao Tan Man Jagao" (Eat Healthy, Think Better) re-position directly addressed this new trend by promising the new generation a healthy and nutritious alternative - that was also delightful and tasty.

Thus, the new logo was born, encapsulating the core essence of Britannia - healthy, nutritious, optimistic - and combining it with a delightful product range to offer variety and choice to consumers

QUALITY AND FOOD SAFETY POLICY OF BRITANNIA

The purpose of this policy is to ensure that we win through quality in market place. This means that we must do everything to ensure consistent delivery of quality products to consumers everytime.

Our commitment quality and food safety will be reflected in every action and is non negotiable. That means:

I. All ingredients used in our factories always meet specified quality standards.

II. All factories and depots maintain high standard of hygiene which ensure that our products are healthy and safe or consumption.

III. Our manufacturing process always ensure delivery of product consistent with products and pack specification which are free from contamination.

IV. Our supply chain practices enable delivery of fresh products to our consumers.

We will fulfill these objectives through:-

• Investing in appropriate technology and equipping oue factories adequately.

• Working collaboratively with our business parteners to create ‘Win-Win’ business outcomes.

• Developing processes which enable consistent delivery of quality products to our consumers.

• Continually training and retraining our employees and business partner to create a culture that values quality and food safety as the core pillars of our business.

PRODUCTS OF BRITANNIA

GOOD DAYBritannia Good Day was launched in 1986 in two delectable avatars - Good Day Cashew and Butter. Over the years, new variants were introduced - Good Day Pista Badam in 1989, Good Day Chocochips in 2000 and Good Day Choconut in 2004.

This rich biscuit enjoys a fan following of consumers across all ages, loyal to the brand promise of a great taste evident from the visibly abundant ingredients. Good Day is amongst the fastest growing brands in Britannia's portfolio and is today the market leader with almost 2/3 share of the market. The brand is synonymous with everyday treats that infuse happiness into people's daily lives.

After two decades of magnificent success; it was time to give the nation yet another reason to have a good day. Abundance, goodness,

indulgence and now unrestrained joy - that is the message of this new campaign.

The new TT ad is the uncontrollable expression of the ticket collector's happiness and joy that is stimulated by consumption of the cookie, that spreads cheer amongst the people around him creating an atmosphere of shared joy that's unorchestrated and straight from the heart. The celebration was taken to the IPL as Good day cheered along with a million cricket fans in the stadiums, each screaming and proclaiming "Ho gaya re Good Day". The dazzling brilliance of this endeavour, the contagious rhythm needs to be lived and spread through the nation, making 'Iska toh ho Gaya Re Good Day' a part of the common lingo and a way of life.

Good Day truly believes laughter and happiness are infectious, it transcends race, caste creed unifying humanity in an inclusive emotion.

The brand perseveres to infuse cheer, hearten the nation and enliven lives. With its rightful place on the front page of The Times of India, Good Day gifts the nation a priceless treasure, that of spreading JOY!

TIGERTiger, launched in 1997, became the largest brand in Britannia's portfolio in the very first year of its launch and continues to be so till today. Tiger has grown from strength to strength and the re-invigoration in June 2005 and more recently, in Apr 2008 has further helped bolster its growth in the highly competitive glucose biscuit category.

Tiger is a Glucose biscuit, which comes with the added goodness of wheat and milk. It is for modern mothers who play an enabling role for their children to compete in today's world and thus want the best. Now Tiger Glucose has been fortified with "Iron Zor" with an attempt towards addressing the Iron Deficiency crisis the children of India face.

Over the years, Tiger has become the mass-market face of Britannia symbolising fun and energy in both urban and rural India, and transcending glucose biscuits.

Tiger Coconut : Delicious Coconut Flavoured Energy Biscuits, launched in 2001

Tiger Creams : Was Introduced in 2002 at just Rs 5 per pack. Tiger Cream is now available in Orange, Elaichi, Chocolate, Pineapple, Strawberry and Butterscotch flavours, and promises to bring more fun

and more energy to children across the country.

Chota Tiger : Is an extension of brand Tiger launched nationally in May, 2007. It is mini sized poppable glucose biscuit with coloured sugar sprinkling. It comes in two variants: Milk Sparkies and Choco Sparkies

Tiger Banana : Britannia is committed to help secure every child's right to Growth & Development through good food everyday. Purposefully taking forward the credo of 'Eat Healthy, Think Better ', we have launched a new variant under our power brand TIGER - TIGER BANANA - power packed with IRON ZOR & and with the delightful taste of banana.

IRON ZOR helps make mind sharper and body stronger. A Rs.4 pack has as much IRON ZOR as that in 1 kg of Banana.

R&D in Britannia has spent considerable time to develop this nutritious and delightful snack for children.

Britannia Tiger Banana packed with IRON ZOR and goodness of Banana is accessible to all, being available in convenient packs priced at Rs.2, Rs.4 and Rs.10.

50-50With a brand name like 50-50, can the product be anything but fun? Launched in 1993, 50-50 belongs to the family of crackers and is considered the "very very tasty tasty" snack.

Britannia 50-50 is the leader in its category with more than one-third of market share. The versatile and youthful brand constantly aims to provide a novel and exciting taste experience to the consumer. As a result, in 2001, the delicious Maska Chaska was launched as a variant of the original brand and became an instant success.

BOURBON

Thick, rich and delicious chocolate packed between two crunchy chocolate biscuits, topped with sugar crystals - presenting, the original Bourbon, from the house of Britannia.

India's first and favorite Bourbon's sweet adventure began in 1955. Since then, Bourbon lovers across the country have been caught opening this chocolate couplet, licking the cream, and nibbling at the melt-in-your-mouth biscuit, bit by bit. Some have been witnessed

chomping it whole, at one go. Some have been noted to alternate it with sips of coffee; others team it with lots of gossip and gupshup, while a few have been observed enjoying it with a book. And some have been seen reluctantly sharing their Bourbon.

Whatever the occasion, wherever the hangout, Bourbon makes for great company. You can grab your very own Nano Pack or a Pocket Pack. The Hangout Pack is just right for chilling with friends. Take along a Party Pack for... yes, a party! And the Gift Pack will surely win you a few brownie points!

MARIE GOLD

Britannia's oldest brand enjoys a heritage that spans the last 50 years - and going strong. In a market swamped with me-too products and where even the name 'Marie' has become generic, Britannia Marie Gold has maintained its stronghold. Today, the ever-popular Marie Gold is synonymous with the 'Tea Time Biscuit'. Its taste, crispiness and lightness make it a must for every tea break. It is the #1 brand in its category by a long shot. MILK BIKISKids may dislike drinking milk, but they love Britannia Milk Bikis! Milk Bikis has been trusted by mothers as a source of growth energy of milk and their loyalty to the brand has made it an integral part of their children's nutrition regimen.

In 1996, Milk Bikis launched a variant called Milk Cream. These round biscuits come with smiley faces and are full of milk cream that makes them very popular with children. Milk Cream also promoted the idea of 'eating milk' in a yummy way, which makes mothers happy as well.

To keep pace with the demands of the new generation and to bring milk nutrition to the masses in a delightful form, Milk Bikis, went one step further in the last quarter of 2006 in providing not just energy but ‘developmental fuel’ for children. With a unique and attractive honeycomb design and an enhanced product experience, the new biscuit is now fortified with SMART NUTRIENTS – 4 vital vitamins, iron and iodine, proven to aid mental and physical development in growing kids.

LITTLE HEARTSLittle Hearts was launched in 1993 and targeted the growing youth segment. A completely unique product, it was the first time biscuits were retailed in pouch packs like potato wafers. The launch message introduced a special taste experience that made the unlikeliest

characters - like Dracula and Frankenstein - melt. In 1997, the 'Direct Dil Se' campaign encouraged youngsters to openly express their feelings. And in 2003, two variants called Little Hearts Chocolate and Little Hearts Sesame were rolled out with a campaign "Dil sabka actually sweet hai". With Little Hearts, Britannia has tasted the sweet taste of success.

The Biscuit Making Process

MIXING: This is a process where all ingredients are put together in right proportion for dough formation.These ingredient are then fed into Mixers where mixing is done and dough is prepared for molding .Major ingredients are flour , fat ,sugar and others as per the product one would like to have.

MOULDING: In this section we laminate the dough into sheet which then passes down to gauge rollers and sheet thickness achieved for cutting . Here we have a cutter or a moulder as per the variety where one gets the shape and sizes of biscuits .

BAKING: This is the area where we pass these moulded wet biscuit into baking oven .The biscuits are baked on desired temperature s.Various type of heating are available now days as per the convenience and cost .Different type ovens are available

COOLING: These baked biscuits are then passed on to cooling conveyors for natural cooling prior to packing .The temperatures are brought down to room temperatures

PACKING: These biscuit are then stacked and fed into packing machine for packing. Different packing material are available for packing of these biscuit in different packs .slug packs , pouch pack or family packs etc. These packs are then put into secondary packaging like cartons to be transported to retailers.

Methods of Mixing:This is a process where all ingredients are put together in right proportion for dough formation. These ingredient are then fed into Mixers where mixing is done and dough is prepared for molding .Major ingredients are flour , fat ,sugar and others as per the product One would like to have..

Mixing can be done in One stage ,two stage or three stage s.

One stage or all in One is type of mixing where all ingredients and water are added once .Mixing is allowed till satisfactory dough is prepared .Normally this type of mixing is used for hard Dough.

Two - Stage mixing :Creaming : All ingredients are added with water and mixed 4-5 minutes except for flour .2nd stage :Flour with chemicals are then mix with the creaming product to form a consistent dough .

Three stage mixing :Stage One : fat , sugar with other ingredient like milk, chocolate, malt , honey etc are mixed and cream is preparedwith portion of water .

Stage two: Salt , chemical and flavours with colors are mixed with water.

Stage three : Flour with water is then added to the prepared cream and mixed till satisfactory dough is prepared .

Mixing process have following characteristics which have be monitored for betterresult .method.Mixing time : Normally any mixing could be achieved within 15-25 minutes .Much depends on mixing speed of mixer , flour characteristic's or temperatures required for dough.

Dough Temperatures : Very important factor the temperature ranges between35 deg c - 42 deg c as per biscuit variety .

Dough consistency: This is done manually by checking dough and stretching the dough it should not break neither should it be so elastic . These

methods are mastered by bakers by trial and error method.

For cracker variety dough are had additional ingredient yeast and dough are kept for 10- 24 hrs .

BAKERY EQUIPMENT AND MACHINERY

MIXERS

• z type single arm mixers

• ztype twin arm mixers

• dual speed mixers

• single speed mixers

• front loading mixers

• top loading mixers

• vertical type- two or three spindle

• Spiral

• Planetary

LAMINATOR

• horizontal laminator• vertical laminator

GAUGE ROLLS

• pre sheeter• two stand rolls• three stand rolls• four stand rolls•

CUTTING MACHINES

moulder

• engraved type• die type•

cutter

• engraved type• cup type

Oven

• hsd/ldo fired type• electric type• direct heating type• indirect heating type• hybrid type• trp• mark I ,II,III

CONVEYOR

• scrap return conveyor• cross conveyor• cooling conveyor• packing table conveyor

METAL DETECTORS & CHECK WEIGHER'S

PACKING MACHINES

• horizontal flow rap machines• vertical pouch feeling machines• cream sandwich machines

PRINTERS AND CODERS

• touch dry type• ink jet type• laser type

GRINDERS AND SIFTERS• sugar grinder• biscuit grinder• flour & chemical sifter

SPRAY MACHINES• oil spray unit• salt and sugar depositors

PUMPS

• Centrifugal pumps• reciprocating pumps• twin lobe pumps• screw pumps• pneumatic pumps

REFRIGERATION EQUIPMENT

• chiller• cold storages• direct expansion type chillers

HEATING EQUIPMENTS

• boiler• hot water generator

MATERIAL HANDLING EQUIPMENTS

• Forklift• pallet truck• power conveyor• floor mobile crane

• trolleys

Food Labels: How Can They Help?Labels are statutory requirement of manufcaturer to disclose information about the food products. The Lable may include the following information:

Sell by date

Expiration date

Lot number

Vegetarian or Non Vegitarian

Recyclable

Environment friendly

Any social message

INSIDE INFORMATIONFood labels and packaging are excellent sources of information about food and guides for food safety. If you don't take time to read them, you are not taking full advantage of this food information resource. Look for the following on food labels and packaging:

Exactly what is in the package. This may includeThe quantity by weight or volume or count.The ingredients, listed in decreasing order. In other words, the ingredient present in the greatest amount is listed first.The form of the food, such as sliced, whole, or chunk.

How nutritious the food is. This may include the number of calories per serving, amount of fat, and percentage of vitamins.How the food should be stored or prepared.The food's shelf-life dates. These may include the date product was manufactured, processed, or packaged.The "sell by" date. This is the last day the product can be sold. It allows time for the product to be stored and used at home.

The "best if used by" date. This is the freshness date; product may be safe after this date but will probably not be at peak quality.The "do not use after" date. This is the expiration date; the last date the product should be used.The lot number of the package. Manufacturers place batch identification numbers on food packages. If there is a problem with a batch of food, news reports will advise people to return products with a certain number.Anti-tampering devices. These will reveal whether the container's original closing has been broken. The name and address of the manufacturer or packer of the food.

PROCESS DESCRIPTION

Reception (Material arrival and analysis):

1. Britannia has laid down their standard specification as per BIS for all raw materials, chemicals and packaging materials. After arrival of material, samples are taken and analyzed in Quality Control Laboratory. After testing if the material is in the range then it is accepted and unloaded otherwise rejected and sent back to the party.

Mixing Section(Sifting and mixing):

1. All ingredients including maida are shifted through fine mesh. Normally 40-70 meshes are used in sifter. After sifting, batch is prepared and mixed in high speed mixer or in vertical mixer.

Production Section:

1. After proper mixing dough mass is passed through a high frequency metal detector if there is any foreign material is in the dough, it will give loud sound and batch is taken for visual inspection. After passing through metal detector dough is rolled by big roller and passed through rotary moulder ehere exact shape of biscuit is given. The weight of raw biscuit is noted down and matched with standard weight required for the process.

2. Then these raw biscuits are passed through tunnek type baking oven of varying length and temperature. It takes approximately 4 minutes for proper baking.

3. Biscuits are baked in ovens and after baking, are cooled on cooling conveyors. One more metal detector is installed to prevent any foreign material in biscuits. If there is any such type of particles in biscuit signal is given and cooling conveyors are shifted forward

hydraulically & the total biscuit are discharged separately and rejected. Otherwise, after OK signal by metal detector, biscuits are automatically lined up by the machine known as stacker. The final moisture content in the biscuit is ranging from 2 to 2.5%.

Packaging Section:1. After stacking, biscuit are automatically fed to the packing

machine without touching by hands. Biscuits are packed in already printed thick wax paper. Then desired number of packets are further packed in poly bags and finally in cartoons.

Quality Assurance Section:1. Final product is then checked chemically and organolaptically for

maitnenance of quality.

BISCUITS AND CLASSIFICATIONThe word biscuit is derived from a Latin word ‘’panis biscotus’’ which means twice baked bread and refers to bread rusks that were made for mariners.

These are baked products made from dough using flour, fats, liquid (water, milk, eggs), salt, sugar, leavening agents and flavouring agents. Based on the dough characteristics 7 dough making procedures, biscuit are of the following two types:-

a) Soft dough biscuits• The dough consists of wheat flour(maida)

obtained from soft wheat, having low protein content.

• Less elasticity• Contains high fat and sugar• Single step method

b) Hard dough baiscuits

• The dough consists of wheat flour(maida) obtained from hard wheat, having high protein content

• Elastic dough• Contains low fat and sugar• Two step method(fermented variety)

RAW MATERIALS AND THEIR ROLE

Flour/Maida:

Important characteristics are given as under:-

a) Primary raw material.b) Flour having low quantity of protein has weak extensible glitenc) Soft and medium hard flour(protein content 8-11%) are used

which are important for gluten development that is responsible for Less resistant to deformation.

d) More extensible Flour used in biscuit making should be free flowing, dry to touch, free from barn particles, creamy in colour, free from fungal infection and other contamination.

Sugar:The Sugar plays very important role during manufacturing of biscuits. Important characteristics are given as under:-

a) when creamed with fats, it helps in incorporation of minute cells in the mixture. Act as antioxitand for fat and increases keeping quality.

b) Sugar caramelizes during the process of baking and thus imparts an appetizing crust colour and improves the general appearance of finished products.

c) Sugar im[proves flavour of the product.d) Particle size of sugar has definite effect on response of dough to

oven heat and on the size and texture of bicuit.Hence it acts as textirizer & also controls of spread of biscuit.

e) Reduces Gluten strength.

f) It, being hygroscopic in nature, assists in moisture retention in the product.

g) It increases the nutritional value of the biscuit.

Fat and Oils:After flour and sugar, the fats and oils are most important ingredient used in biscuit manufacturing. Important characteristics are as under:-

a) In dough they act as shortening agents and texture improvers.b) They help in formation of homogeneous mixture.c) Inhibit gluten formation responsibl;e for shine and softness of

biscuit.

Invert Sugar Syrup:It is made by inversion of cane sugar into glucose and fructose with the help of citric acid. Sweetness of 80%invert syrup is equivalent to ordinary suagar on weight per weight basis. Important characteristics are as under:-

a) It is responsible for browning reaction.b) It helps in decreasing crystalliazationc) It is also responsible for moisture retaining property

of biscuits.d) It provides texture to biscuits.e) It inhibits gluten formation.

Salt:It is most effective concentration is around 0.75units based on the flour weight basis. Beyond this concentration it slows down the rate of fermentation and also onhibits the action of proteolytic enzyme on gluten. Important characteristics are as under:a) It causes strenghthening effect.b) It gives taste to the product.c) It plays role to maintain colour.d) Helps in gluten development.

Skimmed Milk Powder(S.M.P.)Important chjaracteristics are given as under:-

a) Moisture: 4.0%b) Solubility: 98.5%c) S.M.P copmbines with gluten in wheat to produce a soft and

moist product after baking.d) It increases nutritive value.e) Enhances flavour.f) Provides thenderness to biscuits.g) It contains lactose, a reducing sugar which combines with protein

at high temperature during baking giving attractive colour and surface bloom. If S.M.P is not well dispersed in dough the small

lumps will appear as dark brown or black specks in baked biscuits. Hence S.M.P is dispersed thoroughly in cold water before incorporating in the formula.

Ammonium-Bi-Carbonate(ABC):-ABC is extremely volatile salt which when heated liberates carbon-di-oxide, ammonia gas and water. ABC is extensively used forv products which are baked to low moisture contents. Its leavening effect is due to NH3, CO2 and steam due to action of heat.

a) it is leavening agent. It is responsible for puffing.b) It is resoponsible for Maillared reaction as it maintains acidity.

Sodium-Bi-Carbonate(SBC):-It is an important leavening chemical used widely. It produces carbon di oxide in presence of acid component. The acid component reacts with soda, when it gets moist it produces carbon di oxide and steam due to action of heat.

Water:Water is unique ingredient in biscuit dough. Almost all the water added to biscuit dough is subsequently removed in oven, but the quantity of water used have effect on dough consistency. Important characteristics are given as under:-

a) It mainly acts as moistening agents for dry agents.b) It is basic reaction medium for different ingredients

in biscuit dough.c) Helps in homogeneous mixing.d) Helps ih gluten formation.e) Maintains texture of biscuits.f) Affects the stack height.

Sodium-Meta-Bi Sulphate(SMBS):-It is a mellowing agent which breaks the gluten network and softens the dough. It also releases Suphur di Oxide which acts as preservative.

Liquid Vanillin and Vanilla Powder:-Flavour is very important ingredient for baking industry as it performs the following functions.

a) flavour gives rich appetizing taste to product.b) It has a stimulating effect on the digestive system.c) It makes the product of uniform taste.

MANUFACTURING PROCESS

The different types of Raw material used are as under:-a) Maidab) Grinded sugarc) Edible vegetable oil pr palm oild) Inverted Sugar syrupe) Waterf) Skimmed Milk Powderg) Salth) Sodium-Bi-Carbonatei) Sodium-meta-bi-sulphidej) Ammonium Bi-Carbonatek) Soya Lecithin

Preparation procedure:

Collection of Bulk Ingredients(Maida): The Maida from bags is dropped into a pit from where a Bucket conveyor carrying it into mixing compartment. The Maida is passed through a sifter (having six screens) prior to collection in barrels. The capacity of maida sifter is about 360kg per 6 minute.

Sieving is required to be done for the following reasons:-a) To remove impurities and coarse partyicles.b) To make flour homogeneous.c) To aerate the flour.

Collection of Bulk Ingredients(Sugar):-Sugar grinder Power Capacity R.P.MSimple Sugar Grinder

10 HP 600kg/h 2880

Vaccum Sugar Grinder

15 HP 600kg/h 2880

Collection of Bulk ngredients(FAT):- The liquid fat at about 47 dergree celcius is collected in fat reservoir. From the bulk storage tank, this liquid fat is received under the effect of gravity.

Collection of Bulk Ingredients(inverted Sugar Syrup):- The Syrup is conveyed from the syrup plant to mixing section through metal pipes at about 90degree celcius temperature. 74-78 brix sugar syrup is used havind pH of 4-4.8.

Mixing:- Mixing is done in three stages for a batch preparation.

• CREAMING• DRY MIXING • WET MIXING

A) CREAMING:Fat + Emulsifier(Soya Lecithin) + Flavour Mix+ SMP.These are churned strongly sothat the floavour may get adhered to fine droplets of fat. Mixing time is one minute.

B) DRY MIXING:When creaming is over, the Maida and Sugar powder are also poured to creamed fat and mixer is operated for 2 minutes.

C) WET MIXING:

Water + Sugar Syrup + Chemicals(ABC+Salt+SBC+SMBS) mixed in high speed mioxer for 1 minute. Batch is now ready for further processing.

Sahping and conveying to oven:-a) Dough cutting and Metal Detection:h) It mainly helps in crushing of dough into desired consistency.i) There is also a metal detector to detect the impurities like steel,

iron etc.b) Moulder:

Rottary moulder is used for shaping operation. It consists of three rolls and a knife.

FEED ROLL DIE ROLL RUBBER ROLL

FEED ROLL: It is ametal roll. A metal knife is fitted below. The knife helps to cut excessive amount of batch and allow desired amount of weight.

DIE ROLL: It is present between feed roll and rubber roll. It consists of 360 cups which gives the biscuit a specific shape and impression of the brand.

RUBBER ROLL: It is present below the die roll. It helps to pick up the moulded biscuit through the cotton belt or panner web.

Extraction belt:It carries the moulded dough from die.Dough on the extraction belt is prevented from sticking by using steam from lower side of extraction belt.

CROSS CONVEYOUR: The blade remove scrap attached to extraction belt and make it is fall on the cross conveyour, scrap is collected and again put in dough conveyour.

Panning Table Belt: The belt is used to carry moulded dough from extraction belt to wire band.

Baking:It is done in oven. There are 10 Zones in the oven out of which last zone is closed. Chimneys are present in zones for removal of moisture from biscuits. Condensers and exhaust fans are also present at top and bottom.

Puffing: It occurs in ovens during banking. It is result decomposition of Ammonium Bi Carbonate into Ammonia, Carbon, Water.

Ventury system is usedin the oven. Natural gas is used as a fuel. It is Incorporated in oven with air pressure. With the help of sparkers this natural gas is burnt. There are 2 rows of burners-one row is above the wire web acting as upper zone and one below the wire web acting as lowerzone.

Colouring:It occurs during baking. Sugar is responsible for colour development in biscuit at high biscuit. At high temperature sugar caramelizes and imparts crust colour.

Cooling:After the biscuit are allowed to travel on the cooling conveyor for something to lower down the biscuit temperature before packing. For the purpose of cooling there are two cooling conveyors.

Cooling conveyor-I an industrial metal detector is fixed just before the

end of conveyor. cooling onveyor-2

It carries biscuit from cooling conveyor to stacker.

Stacking: A Stacker takes up the biscuits from cooling conveyor and aligns them in rows. The aligned biscuits are fed into auto feeding machines to packing machine. A brush roll is fitted above the stacker to control the movements of biscuits.

Packaging: packaging is done by packing machines. The machine automatically wraps the wrapperas around the biscuits. Sealing of biscuits is done with the help of roller heaters. Some heaters are used for side and some from cross sealing (lengthwise)

FLOW CHART OF BISCUIT MANUFACTURING PROCESS

Flour sieving + Sugar Grinding

↓ Slurry Preparation (Maida +Sugar yeast +Chemicals + Water)

↓ Batch Weighing

(Addition of more ingredients- Maida, sugar, fat, scrap, sugar syrup, salt, SBC, SMBS, ABC, Flavour etc.)

↓ Mixing In Dough Mixer(10-12 minutes)

↓ Laminating

↓ Sheeting and Maida Spreading

↓ Brushing Contd.

↓

Moulding

↓ Baking

↓ Spray Field Oven

↓

Oil Spraying

↓ Cooling

↓ Packaging

QUALITY ANALYSIS:

Maida:Special care is taken to mtest maida as it is an important ingredient used in biscuit making and its property affects the biscuit quality. For example, if excess bran is present in maida , it will impart dark colour to dough which will further affect the biscuit colour and texture. Soft and medium hard maida is used for biscuit processing, maida is tested for various properties in lab which are:

a) DETERMINATION OF GLUTEIN CONTENT:The Strength of flour depends upon both the amount and physical qualities of glutein. Crude glutein obtained in this way contains, albumin, glutein, globulin,gladin and protease.

% glutein (on dry wt. basis)= M2-M1x100where,M1=mass of empty dish

M2=mass of dish with dry glutein

M3=mass of dish with sample

b) SEDIMENTATION VALUE: The volume of se