INDUSTRIAL TRAINING

Submitted to: Dr. YS Dhaliwal

Submitted by: Arpna

H-2014-05-007

Department of Food Science , Nutrition and Technology

College of Home Science

CSK HP KV Palampur (Himachal Pradesh)

PREFACE
Last 4 months of my training were at MONDELEZ INDIA FOODS PRIVATE
Ltd. Phillaur. It was really heartening and satisfying. My training period was
divided into two departments:-

 Quality control department

 Production department

I have done my training in production section. In this period prepared the

introduction of industry, procedure manufacturing and processing of
Cadbury bourn vita and Oreo. Done testing in quality lab and other projects.

INDEX
1. Introduction.
2. Process Flow Diagram.
3. Raw Material Storage.

4. Function and Specification of Raw Materials.

5. Quality Check of Raw Materials.

6. Testing of packing materials.

7. Raw Material Section.
8. Premixing Section.
9. Mixing Section.
10. Rotary Section.
11. Packaging Section.
12. Quality Assurance of Mondelez.

INTRODUCTION
 The word biscuits are derived from the French word meaning ‘twice cooked’.
This lengthy cooking and processing derived out biscuits so well before the days
of airtight containers. Today shops offer a vast range of well flavored biscuits in
eye-catching packets but few can complete with the flavors, texture and aroma of
the freshly baked variety. Biscuits may be defined as a product based on cereals
(more than 60% of its weight) and contains less than 4% moisture and has
undergone several processing such as mixing, dough development, cutting etc.
and finally baked in an oven at a suitable temperature.

Biscuits Industry in India:

Bakery industry has an important place in the industrial map of our country. The
annual turnover at present is estimated at over 2000 crores. The bakery industry
comprises mainly of bread, biscuits, cakes and pastries manufacturing units. The
contributing factors for popularity of bakery products are:-

 Urbanization resulting in increased demand for ready to eat

convenient products.
 Availability at reasonable cost.
 Greater nutritional quality.
 Availability of varieties of different textural and taste profiles and
better taste.

There are50 large-scale units producing either bread or biscuits. Among these, 21
units produce only bread, while the remaining products biscuits. The number of
bakery units is maximum in western region(34.2%) and minimum in eastern
region. The per capital consumption of bakery products is high in
MAHARASTRA, PUNJAB followed by NEW DELHI & WEST BENGAL.
Mondelez India food private limited:-
Mondelez international is an American multinational confectionary, food, and
beverage conglomerate based in Illinois. It consists of the global snack and food
brand of former Kraft food. The Mondelez international’s portfolio includes
several billion- dollar brands such as Oreo, chips, TUC, Belvita, Triscuit, LU,
Nabisco, Peek freans(cookies and crackers); Milka ,Terry’s , Toblerone, Cadbury,
Marabou, Fry’s, Chiclets, Halls, Stride, and Tang.

Oreo:-

Oreo is a sandwich cookie consisting of two chocolate wafers with a sweet crème
filling in between, and are marketed as “chocolate sandwich cookies” on the
package in which they are held . The version is currently sold in the India is made
by the Cadbury division of Mondelez International. In India Oreo is first launched
in December 2010. Oreo is the one of the best selling cookie of the United States
since its introduction in 1912. In 2012 Oreo celebrates its 100th birthday.

Oreo biscuits are available in three flavor in India they are chocolate , vanilla and
Orange. The flavor of sweet crème is changed. World wide it is available in many
flavor .

Bournvita biscuit:-

The Introduction of Bournvita biscuit is a product of innovation and caters to a

new taste, it is blended with bournvita as a finished good in a good amount. It is
launched in India 28th March 2016. It is a new product to Indian Market. It
launched with a tag line – “ Subah ka Biscuit ”
 Process Flow Diagram:-
Flow Diagram of Oreo production

Receiving & storage of

ingredients

Invert syrup preparation Pre-mixing Process water

Sugar grinding Mixing Reworking

Metal detector Dough moulding

rejection

Cream preparation Baking & sandwiching

Metal positive
dough Nonusable Cooling Tunnel

MD

Packing

Storage & dispatch

 Flow Diagram of Bournvita biscuit production.

Receiving & storage of

ingredients

Invert syrup preparation Pre-mixing Process water

Mixing Reworking

Metal detector Dough moulding

rejection

Baking

Metal positive
dough Nonusable Cooling Tunnel

MD

Packing

Storage & dispatch

Raw Material Storage:-

Raw material required for Cadbury bourn vita.

Sr. No. NAME OF INGREDIENTS

1. Wheat flour (Maida)

2. Sugar
3. RPO(Refined palm oil)
4. Salt

5. Invert syrup
6. SMP(Skimmed milk powder)
7. SBC(Sodium Bicarbonate)
8. Bourn Vita

9. ABC(Ammonium Bicarbonate)
10. Lecithin
11. Water
12. Fresh milk flavor

13. (CSS-DC)Caramel
14. Nutrient slurry
15. (RDC)Red Dutch cocoa
16. Choc éclair flavor

17. Toffee flavor

Raw material required for Oreo.

 Sr. No. NAME OF INGREDIENTS

1. Wheat flour (Maida)

2. Sugar

3. RPO(Refined palm oil)

4. Salt

5. Invert syrup

6. Vanillin

7. SBC(Sodium Bicarbonate)

8. ABC(Ammonium Bicarbonate)

9. Lecithin

10. Water

11. (RDC)Red Dutch cocoa

Function and Specification of Raw Materials:-

Flour/Maida:

 It is primary raw material

 Most biscuits are prepared from flour-which has low quantity of protein and
weak extensible gluten
 Soft and medium hard flour(protein content 8-11%) is used which gives gluten
that is less resistant to deformation
 More extensible
 Dough is rubbery
 Flour used in biscuit making should be free flowing, dry to touch, free from
visible bran particles, creamy in color, free from musty flavor and rancid taste,
fungal infection and other contaminations.

Soft Wheat flour is used for following reasons:-

 Soft wheat flour is used because it will give more tender biscuits then hard
wheat flour.
 The flow or spread of biscuits dough during baking is taken as a measure of the
flour. Quality is much greater using soft wheat flour.
 During milling of hard wheat more of starch granules get damaged and they
loss their order and crystal nature.
Sugar:
 It should be clear &less moist.
Functions:-
 It provides sweetness to the biscuits.
 On Caramelization during baking, it imparts a peptizing crust color and
improves the appearance of biscuits.
 On creaming with fat. It helps in incorporating minute air cells in the mixture.
These minute air cells from the nucleus for leavening action, which ultimately
contributes to volume. It tenderizes flour proteins.
 Improves the flavor of the product, makes biscuit hard.
 It controls the spreading of biscuits(spreading increases with increasing sugar).
 Sugar contributes the nutritional value of biscuits and it is a quick source of
energy.
 Sugar also affecting eating texture by increasing the crispness of biscuits.
Fat:
 It should have low acid value & peroxide value.
Functions:-
 Fat helps in reducing toughness of dough formed by mixing Maida and Water.
 Fat prevents gluten formation by insulating the gluten forming proteins from
the water, hence a less tough dough results.
 Fat provides sensory attributes e.g. moistness, crispness and crunchiness.
 Fat lubricates the gluten formed, allowing it to slip into a new position when
sheeted or formed into biscuits shapes, without the same desire to return to its
original position.
 It contributes to product flavor and carries flavor.
 It gives palatability to the baked products and help in the development of
particular structures like volume expansion, uniform granular structure, good
texture, fakeness etc.,besides giving food value to it.
 Facilitate aeration.
 They interact with starch components to alter hydration and swelling
properties.
 Fat performs the function of shortening and textural function in dough so that
the biscuits are less hard and good to eat.

Skimmed Milk Powder:

 It should be free from lumps and should be odorless.

Functions:
 It is widely used for the flavor and textural improvements.
 It is also provides the nutritive value of the product.
 It is also used to aid surface colorings to the product.

Water:
 Water is a unique ingredient in biscuits dough. Almost all the water added to
biscuit dough is subsequently removed in oven, but the quantity of water used
may have an effect on the dough consistency that is why tap water used is
treated properly prior to use in dough making. In Bournvita biscuit plant water
is treated by reverse osmosis plant to achieve required hardness and TDS (total
dissolved solids) water is added at a low temperature to the other ingredients.
Functions:
 It influences the dough handling properties theological/mechanical properties
of the dough system.
 It acts as medium for various reactions and interaction such as gluten
development,starch,gelatinization,dissolution of water soluble components,etc.
 Act as a medium for heat transfer during baking.
 Affects storage life of raw as well as finished product
Ammonium Bi-carbonate:
 Ammonium bicarbonate is an extremely volatile salt which when heated
liberates carbon dioxide, ammonia gas and water. The major advantages of
using is that it does not leave any residue after its action.
 It is a leavening agent, which is responsible for puffing.
 It is responsible for color.

Sodium Bi-carbonate:
 It is an important leavening chemical used widely under acidic conditions used
for co2 release during baking and adjusting pH of the dough and biscuits.
Functions:
 Sodium bicarbonate acts as a high baking temperature.
 It acts at low temperature and helps in puffing of the biscuits resulting in a
product which is light and porous.
 Sodium carbonate(washing soda) has a marked softening action on gluten.
 Under acidic conditions, used for carbon dioxide release during baking and
adjusting pH of the dough and biscuits.

Salt:
 It should clear, free from moisture and free from foreign particle.
Functions:
 It causes strengthening effect.
 It gives taste to product.
 It is used mainly for its flavor and flavor enhancing properties.
 It toughens gluten and gives less sticky dough.
Flavor:
Functions:
 Flavor gives rich appetizing taste to product.
 It has a stimulating effect on the digestive function.
 It imparts a typical and unique flavor and taste to the biscuits.

Citric Acid:-
 Functions:

 It is used for the inversion of sucrose to glucose and fructose.

 It also helps in preparation of CO2 from untreated NaHCO3 (as on heating only
half of the NaHCO3 liberates CO2,rest remains untreated)in an oven.

RDC (Red Dutch cocoa):-

The RDC comes from a process in which the roasted, shelled and nibbed beans are
treated with alkali.
Functions:

 It provides color and flavor to the baked product.

 It increases the pH slightly.

Soy Lecithin:-

Lecithin is a generic term to designate any group of yellow –brownish fatty

substances that occurring in animal and plant tissues, which are amphiphilic-they
attract both water (and so are hydrophilic ) and fatty substances (lyophilic) ,and are
used for something food texture dissolving powders( emulsifier) ,homogenizing
liquid mixtures, and repelling sticking materials.
Functions:
 It works by providing bridge between two phases.
 It promotes many of the required properties.

Caramel:-

Caramel is beige to dark brown confectionary product made by heating a variety of

sugars.
Functions:

 It provides flavor and color.

Bournvita:-Bournvita is one of the finished good is used as a raw material for
production of Bournvita biscuit. Its function is to give specific taste.

Quality Check Of Raw Material:-

All raw materials received undergo a quality check before storage/use. The
Quality Assured department conducts these tests. If the raw material is not
found according to the specifications of Mondelez then it is rejected and sent
back to the supplier. The raw materials are first checked for physical
parameters like Color, Odor, taste and presence of any foreign or extraneous
material. Then they are tested for various chemical and functional properties.

The common tests performed on raw materials are:

Maida:

 Moisture content
 Gluten content
 Sedimentation value
 Water absorption power(WAP), and
 Ash content.
 SRC(Solvent retention capacity).
 Alveograph P/L & W value.

Fat:

 Melting point
 Acid value
 Peroxide value
 SMP:-

 Moisture
 Acidity

Sugar Syrup:-

 Bricks
 Water insoluble matter and
 pH

Finished goods:-
 Fat
 Ash
 Acidity of extracted fat.

Raw Material Test Methods

1. Wheat Flour /Maida

1.1 Determination of moisture content

Apparatus: Petri plate, electric oven,desiccators,weighing balance

Procedure:
Take the weight of empty Petri plate
↓
Take 5 gm of sample and note down the weight
↓
 Place the dish in an electric oven maintained at 130°C to 133°C for 120 minutes.

↓
After that remove & place the dish in an desiccators.

↓
Take the weight of dried sample & calculate % moisture content.

Calculation:
Moisture, percent by mass= 100(M1-M2)/M1-M
Where
M1=mass in gm of the Petri plate with the sample before drying.
M2=mass in gm of the Petri plate with the material after drying ,and
M =mass in gm of the empty Petri plate

Standards: 14% Maximum

1.2 Determination of total Ash:-

Apparatus: weighing balance, silica crucible, burner, muffle furnace, desiccators.

Procedure:
Take the weight of empty crucible
↓
Take 5gm of sample in the crucible
↓
Slowly incinerate over the burner till the results
↓
Cool in desiccators
↓
Note down the weight & determine the total ash
Calculation:
Total Ash (on dry basis),%by mass=100 (M2-M)/M1
Where
M1 =mass in gm of the crucible with the dried sample
 M2 =mass in gm of the crucible with the ash
M=mass in gm of the empty crucible
Standard: 1.6%

1.3 Determination of water absorption:

Apparatus: Weighing balance ,Porcelain cup ,Burette , Spatula
Procedure:

Take 25 gm. Of Maida sample

↓
Fill the burette with water
↓
Add the water drop wise & continuously mix the sample with spat hula
↓
Mix the sample with water till the soft dough formed
↓
Record the reading of water used for the preparation of soft dough in burette.

Calculation:
%age absorption=volume of water required×100/weight of sample

Standard: 54-60%
1.4 Determination of gluten:

Apparatus: Weighing balance, bowl (big), silk cloth with an aperture, Iodine
solution, spatula, oven, desiccators
Procedure:

Take the dough from WAP

Place this dough in water for about 1 hour

Place it in piece of silk cloth with an aperture of 150 micron sieve

 ↓

Wash it till the water passing through the silk does not turn blue when a drop of
iodine solution is added to

Keep in hot air oven at 105°C for 4 hours or 130+3°C for 120 minute

Remove & place in a desiccators till cool and weight

Calculation:

Gluten(on dry basis),percent by mass=100(M2-M1)/M(100-M3)

Where M1=mass in gm of the empty dish,

M2=mass in gm of the dish with dry gluten.

M=mass in gm of the sample….

M3=%age of the moisture in the sample.

Standard:7-10%

1.5 Determination of sedimentation value:

Apparatus: Measuring cylinder (50 ml),weighing balance. Sedimentation shaker

apparatus, measuring cylinder (50 ml)
Procedure:
Take 3.2 gm of the wheat flour in a 100 ml glass stopper graduated cylinder
↓
50 ml water in graduated cylinder
↓
Add few drops of bromophenol solution & place the stopper
↓
Put it on sedimentation shaker for 5 min.
 ↓
Remove from sedimentation shaker & add 25 ml lactic acid
↓
Again put it on sedimentation shaker for 5 min.
↓
Remove from sedimentation shaker & rest for 5 min.
↓
After 5 min. note down the treaded\in in graduated cylinder
Standard:20-24 ml.

2. Butter:
2.1 Determination of acidity:

Apparatus: Conical flask, measuring cylinder (50 ml), pipette (1ml), weighing
balance

Reagent:

1) Standard 0.1N NaOH solution

2) Phenolphthalein indicator of pH 8.2-9.8

Procedure:

Weight accurately about 10-gms of samples in a conical flask.

Add 50 ml. of hot distilled water and shake the contents.

Phenolphthalein indicator (2-3 drops)

Titrate it with 0.1N NaOH solution to light pink color & note down the reading
Calculation:

Titration acidity %=(9×N×V)/W

Where N=Normality of NaOH sol.

V=Volume in ml. of NaOH used for titration.

W=Wt. of sample in gms

2.3Detemination of salt

Apparatus: Pipette (1ml), conical flask, measuring cylinder (50ml), weighing

balance

Reagents

 Potassium chromate indicator 5%(w/v) in water.

 Standard 0.1 N AgNo3

Procedure:
1 gm of sample
↓
Add 20 ml distilled water
↓
Add potassium chromate as an indicator(Initial color – yellow)
↓
Titrate with 0.1 AgNo3 to light red color

Calculation: 5.8×N×V/Wt. of sample

Where
N=Normality of AgNo3
V=volume in ml. of AgNo3 used for titration

3.Liquid vegetable oil:

3.1Determination of acid value
Apparatus: Conical flask (250 ml), pipettes (1 ml), beaker (100 ml), weighing
balance

Reagents:
Ethyl alcohol, Phenolphthalein indicator sol, Standard aqueous potassium
hydroxide or Sodium Hydroxide Solutions

Procedure:

50ml. of ethanol in conical flask

↓
Phenolphthalein indicator of pH 8.2-9.8
↓
Neutralize with NaOH 0.1 to pink color
↓
Add 10 gm sample in titrated solution
↓
Titrate with NaOH 0.1 & note down the reading

Calculation:
Acid value = 56.1×N×V/wt of sample
Where V=volume in ml of standard potassium hydroxide or sodium hydroxide sol.
Used,
N= normality of standard potassium hydroxide sol. Used,
W= weight in gm of the material taken for the test.

3.2Determination of peroxide value

Apparatus: conical flask (250 ml), pipettes(1ml), beaker(100ml), Spatula,

beaker(50ml), burette, test tube, weighing balance.
 Reagent: Acetic acid, chloroform sol, potassium iodine sol, sodium thiosulphate,
solution starch solution 1%.

Procedure:
Take 5 ml of sample

Add 30 ml of acetic acid: chloroform solution(3:2)

K I(potassium iodide) saturated

Rest for 1 min. with covering

30 ml distilled water

Starch indicator(2-3 drops)

Titrate with sodium thiosulphate(to creamy white color)

Calculation:

Peroxide value = 1000×N×v/Wt. of sample

Standard:1.0-1.5 %

4 Skimmed milk powder:

4.1. Method of determination of moisture content in the milk

Powder (IS:11623-1986) ( Gravimetric method)
Apparatus: Flat bottom moisture dishes of stainless steel, drying oven,
desiccators.

Procedure:-
Take the weight of empty stainless steel
↓

take 5gm of the sample & again note down the weight

Place the dish in an electric oven maintained at 130°C to 133°C for 120minutes

After that remove & place the dish in a desiccators

Take the weight of dried sample & calculate % moisture content

Calculation:

Moisture % by mass= M1-M2×100/M1-M

Where………

M1 = Initial mass in gm of the dish and lid with sample

M2= Final mass of dish in gm of the dish and lid with material after drying

M= Mass in gm of empty dish.

Titrable acidity:
Apparatus: - Conical flask, measuring cylinder, pipette.

Procedure:-
 10 gm sample + 90 ml lukewarm water in conical flask

Take 20 ml of this solution and add phenolphthalein indicator

↓
shake well and titrate against 0.05N NaOHsoln
↓
Calculate acidity in terms of lactic acid.

Formulae:-
% acidity (by mass of LA) = 4.5×A×N
Where
A= volume of NaOH

N= Normality of NaOH solution.

4.2. Determination of total ash:-

Apparatus: Flat bottom dish – silica (50 ml), Muffle furnace - maintained at 550
+/- 10 °C, Desiccators

Procedure :

Take the weight of empty crucible

Take 5 gm of the sample in the crucible

Slowly incinerate over the burner till the smoke comes

Then put the sample in a muffle furnace maintained at 540°C + 10°C until grey ash
results
 ↓

Cool in desiccators

Note down the weight & determine the total ash

Calculation :

Total ash % by mass = 100 (M2 - M ) / M1 –M )

Where
M2 =wt. in gms. Of dish with ash
M1 = Wt. in gms. Of dish with the powder
M= Wt. in gms. Of empty dish.

5. Biscuit

4.1Determination of moisture:

Apparatus: Moisture dish aluminum, Oven Electric, maintained at 105 +- 1.e,

desiccators

Procedure:
Take the wt. of empty aluminum dish

Take 5 gm of the sample & again note down the wt.

↓
 Place the dish in an electric oven maintained at 130°C to 133°C for 120 minutes

After that remove & Place the dish in desiccators

Take the wt. of dried sample & calculate % moisture content

Calculation:

Moisture present by mass = 100 (m1 – m2)/ M1-M

Where
M=mass in gm of the empty disc
M1=mass, in gm of the empty disc with the material before drying; and
M2=mass, in gm of the empty disc with the material after drying to constant mass.

5.Determination of extracted fat :

Apparatus: Soxhlet apparatus with a 20 ml flat bottom flask, thimbles, weighing

balance, pestle & mortar, spatula

Reagent:
 Phenolphthalein reagent 1.0 % in ethanol (95 % )
 M potassium Hydroxide Solution.
 Ether ethanol (90 %) stock solution.
 Petroleum ether (90 %) stock solution.
 Equal volume of ethanol – ether which has been neutralize to
phenolphthalein with 0.1
 Potassium Hydroxide
  Flat bottom flask

Procedure :

Take the wt. of empty flat bottom flask

↓
Take the wt. of empty thimble + cotton
↓
Take the wt. of sample in grinding form + thimble
↓
Put the thimble in soxhlet apparatus
↓
Fill the apparatus with two siphon petroleum ether
↓
Switch on the water supply & apparatus also for about 4hrs
↓
After that remove the flask for 1 – 2 hours & thimble.
↓
Place thimble in oven for further use
↓
After 1-2 hrs. Weigh the wt. of flask & calculate the fat.

Calculation:

Extracted fat, % by mass = A-B/C*100

Where
A =wt. of flask + wt. of extracted fat.
B = wt. of empty flask.
C = wt. of sample.
Acidity of biscuit from extracted fat :

Reagent :
 Phenolphthalein reagent as an indicator.
 0.05 N Sodium hydroxide solution.
 Ether ethanol (90 % ) stock solution.
 Petroleum ether (Boiling point 40-80 )

Apparatus : Conical flask , Weighing balance, measuring cylinder (50ml ), pipette

(1 ml ).
Procedure :

Take 25ml ethanol and 25 ml petroleum ether ,now add 3-4 drops phenolphthalein
indicator of pH 8.2-9.8 after that titrate the solution with NaOH0.05N and note
down the reading weight of sample, tare the weight after that add the fat obtained
from soxhlet apparatus now note down the weight of fat again titrate the solution
with NaOH 0.05N and note down the reading.

Calculation:

Acidity of biscuit = 1.41 * 1st titration 2nd titration / weight of sample.

Standard :
For fresh biscuit = 0.2-0.5 %

pH of biscuit :

Apparatus : pH meter, measuring (50 ml ), weighing balance

Procedure :
 Take 50 ml distilled water in measuring cylinder add 5 gms of biscuit in grinding
form mix the biscuit and water properly now place this the solution under the PH
meter and note down the reading.

Standard: 6.5-7.3

5 Sugar.

5.1Moisture of sugar :

Apparatus: Petri dish, weighing balance, oven, desiccators

Procedure:

5gm sugar weighed in dried Petri dish.

Keep in oven and maintained at 110+- 1°C for at least 2 hrs.

↓
Cool in desiccators and weigh.
↓
Repeat the drying, cooling and weighing process till difference between two
consecutive. Readings is less than 1 mg.

Calculation:

Moisture, percent by mass = 100 (M1 – M2) / M1-M

Where
 M1 = mass in gm of the Petri plate with the sample before drying.
M2 = mass in gm of the Petri plate with the material after drying, and
M = Mass in gm of the empty Petri plate
.
6 Invert syrup :
Acidity of invert syrup :

Apparatus: Weighing balance, measuring cylinder (50 ml), Heating plate pipette
Procedure:

5gm sugar syrup + 50 ml distilled water

↓
Warm the solution lightly for easy dispersion of syrup and water.
↓
Titrate with 0.05N NaOH using phenolphthalein as indicator.
↓
End point marked by change of light yellow color of syrup to light pink color.

Calculation:

% ACIDITY = 4.9 * N * V *100/W

WHERE
V= volume of NaOH USED (ML)
W= wt. of sugar syrup (gm)
N= normality.

7 Ammonium bi carbonate
8.1Determination of purity:
Apparatus: Weighing balance, measuring cylinder (50 ml), pipette, and conical
flask.
Procedure:

2gm sample in conical flask

↓
50ml distilled water
↓
Methyl orange as an indicator
↓
Titrate with 0.1N HCL to reddish color

Calculation:

V=volume of HCL used (ml)

W = wt. of sample (gm ).
N= normality of HCL.

8 Sodium bi carbonate.
8.1Determination of purity :

Apparatus: Weighing balance, measuring cylinder (50 ml ), pipette, conical flask.

Procedure:

2gm sample in conical flask.

↓
50 ml distilled water.
↓
Potassium chlorinate as an indicator
↓
Titrate with 0.1 N HCL to reddish color.
Calculation :

SBC (% BYMASS )= 8.4 *V * N/ W

Where
V= volume of HCL used (ml)
W=wt. of sample in gm.
N= normality of HCL.

Testing of packing material:-

A)Laminate:
1. GSM(gram age square meter): cut 10cm*10cm square pieces of laminate
with the help of square block. Weigh the individual cutting on the weighing
balance.

G.S.M. = wt. of 10cm*10cm piece/100

2. Bond strength:
 cut the sample of size 15mm*200mm of laminate strip

 delaminate both the layers carefully using the solvent toluene

 once delaminate, clamp the sample on the bond strength testing machine

 now check the meter reading zero, if not rest the indicator by pressing the
zero button on console

 now start the meter button

 after the peeling begins note down the maximum value of the laminate.

 Also record the mode of failure

3. Seal strength:
 cut the sample of size 15mm*200mm of laminate strip

 fold the strip from the mid and seal it with the help of sealing machine.

 once sealed, clamp the sample on the bond strength testing machine.
  now check the meter reading zero, if not rest the indicator by pressing the
zero button on console

 now start the meter button

 check for the readings of force on meter require to break the seal.

4.Artwork, shades, dimensions and mandatory requirements.

B).Polybags
1. Gauge: weigh 25-30 pieces of polybag, calculate average weight per piece.
Measure dimensions of the polybag(length and breadth) in inches with the help of
measuring scale and calculate area in square inch.

Gauge =average wt. of polybag (in gram) *3300/area in square inch

2. weight/piece, count/kg and proper opening

C).Tape
1. Roll length: unwind the roll and cut exactly one meter length of the piece.
Unwrap and place 10-15 such lengths of the previously opened length. Measure
total no. of lengths. Remove the air bubbles entrapped if any by making pinholes,
weigh these lengths altogether.

Length per roll = wt. of length altogether*(wt. of roll in g-core

weight)/no.of lengths

2. Film thickness: combine two layers of the tape by adjoining the adhesive
sides together. Measure the thickness of the film with the help of micrometer.
Divide the observed value by 2 to get the final thickness.

3. Adhesive strength
C). Corrugated fire box:
1. G.S.M.
2. Dimension, art work, moisture, weigh, bursting strength, mandatory
requirement.

D). Display outer and tray:

The packing material is weighed in a weighing balance and weight is recorded, art
work and dimensions, GSM also.

Physical tests:
1. Gauge: control of gauge is important for biscuit packing if gauge get out of
order then there is in packing problem ultimately decrease the no. of biscuit. For
measuring gauge take a specified number of biscuit. Arrange the biscuit and
measure the gauge with help of Vernier caliper. Record the reading in in-processes
controller chart. Compare with the biscuit slandered and take the necessary action
if need.

2. Weight: weight is an important parameter for the quality. If the weight deviate
from it’sstanderd this will ultimately decrease the overall quality of the biscuit. For
measuring the weightr take the specified number of biscuit according to variety
and weight the biscuit by using weighing balance. Note the reading in process
controller chart. Compare with the biscuit slandered. Take necessary action if need.

3. Dimension: dimension is a critical parameter to measure the quality of biscuit.

If the dimension changes, appearance of biscuit packet will also change thus
decrease the overall quality of biscuit. Dimension of biscuit is measure by using
Vernier caliper. Record the reading in process controller chart and compare with
the standard.

4. Color: color of the biscuit is the most important parameter from the consumer
point of view. Color should be uniform throughout the product. For testing the
color take the biscuit sample and compare with the standard color in the bright
light. The edge of the biscuit should not be dark also the color should be same at
top at bottom.
Chemical test:
Moisture content:
Weigh the empty petridish

Take 10mm*10mm sample and weigh it

Previously dried in an oven at 105degree C for 15 minutes

Cool in desiccator and weighed

Note down the final weight

Calculation:

Moisture content = ( initial weight of 10mm*10mm sample sample – final

weight) / initial weight

Raw Material Section:-

In raw material zone there is provision of storage of all required raw material and
there is setup of Miranda system for dumping of wheat flour (Maida) and sugar.
There is continuous dumping of wheat flour then it is send to silo that has fix
storage of wheat flour as per batch requirement. Wheat flour is send by pneumatic
pressure to silo then to mixer. Sugar is also send by pneumatic pressure to
premixing section. All other ingredient is send manually to premixing section. The
raw materials are stored to meet the requirements of next2-3 days.
Maida Dumping and Sifting:-In the manual methodthe Maida bags are unloaded
in the Maida hopper from where it is transferred to the sifter from where any other
foreign matter are removed with the help of sieves (40 and 32 mesh number) .Then
Maida passes through magnet which remove the metal pieces present . The Maida
is then transferred to the Maida service tank(silo)from where it is send to the
mixing section.

Sugar Dumping:-
The sugar bags are unloaded in a hopper manually from where it passes through
magnet which removes the metal pieces present in the sugar. Sugar used for
grinding should contain low moisture content. This sugar is transferred to the pre-
mixing section and in the tanker where invert sugar is prepared. In the premixing
section sugar is grinded with the help ball mill hammer then it is dumped to
creamer.

Premixing Section:-
In premixing section all ingredient are dumped into mixer and creamer from above,
according to recipe ratio. The other functions carried in premixing section are
weighing of chemicals.

In premixing section some ingredient are dumped into creamer in their

respective amount and order and some are in mixer directly.Ingredients that are
dumped into creamer according to their dumping order for Bournvita biscuit are

Sr.No. Material Name

1. ABC
2. Salt
3. Caramel
4. Milk flavor
5. Toffee flavor
6. Choco éclair
7. Nutrient Mix
8. Soya Lecithin
9. Invert syrup
10. Water
Some ingredient are first dissolved with water then dumped to creamer such as
ABC and salt such that Lecithin is first dissolved in 2 liter palm oil then dump.

Ingredients that are dumped directly to mixer are RDC, SMP, SBC, Bournvita and
Rework (broken). The reason behind the dumping of these ingredients directly to
mixer then creamer are that they all are in powdered form and viscous in nature so
they can block the passage when cream is send from creamer to mixer.

Mixing Section:-
Mixing Section is the heart of baking industry. It is the section where all the raw
materials according to the recipe are mixed and dough is prepared. If there is any
problem in dough or defect found in the biscuit it is controlled by a change in
recipe from premixing section. The functions carried in mixing section are
preparation of cream of ingredient that are dumped into creamerand palm oil is
also added in this ,with the help of mixer &this process is known as creaming.
Creaming is done for about 8 minute.

After creaming the cream is send to mixer through pump then other ingredient are
added to mixer directly from premixing section then fast nixing take place for 3
minute and then wheat flour according to its recipe is added then slow mixing take
place for 3 minute this whole process is known as mixing. The Mixing can vary
according to the environmental & mixing conditions of batch. After that dough is
prepared & temperature is noted which should be about 30-34°C. After that dough
is transferred to the trolley and with this trolley the dough is dumped into the
hopper of rotary.
 Mixing Contributes in:-
 Blending ingredients together to form a uniform mass.
 Dispersal of a solid in a liquid or liquid in a liquid.
 Dissolving solid in liquid.
 Kneading the mass to impart the development of gluten from flour proteins in the
presence of water.

Rotary Section:-
In the rotary machine manipulation of the unit piece to conform to a particular
product concept. The rotary machine comprises of

1. Dough Feeder Roll.

2. Dough Feeder Web.

3. Star Wheel.

4. Metal Detector.

5. Rotary Moulder.

6. Endless web.

7. Panner Web.

8. Bendrum Web.

Dough Feeder Roll:-

Dough is first dumped to dough feeder roll via hopper in this .This has slow
moving full width conveyer belt in the bottom that feed the bulk dough into a pair
feed rolls that breaks up and partially sheets in.

Metal Detection:-

Dough is passed through a metal detector which is fixed just above the vertical belt
conveyor. It can detect all types of metallic materials. If a metallic particle is
present in dough, metal detector produces a characteristic sound and the dough is
immediately removed from the vertical conveyor manually or automatically. This
is one of the critical control points. The metal detector is checked for its efficiency
for every two hour. We check the efficiency by three metal probe first is 1.5mm
ferrous which is the maximum passing limit second is 2mm nonferrous and third
one is 2.5mm stainless steel.

Rotary Moulder:-

The rotary moulding machine consists three roll that is feed roll, rotary die and
rubber roll(pressure roll). The rotary molding machine consists of a hopper and at
its base the feed roll and rotary die rotate towards each other. The front roll of the
Moulder has engraved cavities into which the dough is forced, and the function of
rear roll is simply to help force the dough into the cavities. Pressing against the
engraved roll is a scrapper knife which also helps force the dough into cavities. But
its main function is to trim off the excess dough so that the cavities are filed but not
over filled. As the engraved roll, with the cavities with dough continues to rotate, it
is also the rear member of a conveyor which includes a canvas belt. As the
engraved roll comes into contact with the third roll that is rubber roll. It is actually
the canvas belt that it contacts. When contact is made, the belt pushes very hard
against the dough in the engraving with the result that the dough then sticks to the
belt dropping them onto the endless band.

There are 24 rows present on the die roll. Each row is having 15cups. Hence in one
revolution 30×15 biscuits are moulded. Speed of rubber roll is more than die roll to
maintain the specific length of biscuits.

Endless web:-

This belt is used to convey molded dough from die roll to panning table belt. A
scrap knife is used to removes scrap adhering to the endless belt. Scrap falls on
cross scrap conveyor belt. Scrap is collected in tray.

Panner web:-

This is used to carry molded dough from extraction belt to wire-net conveyor. It
can serve following functions:

 Increasing speed of panning table belt can increase length of moulded

dough.
  For proper placing of moulded dough on the wire-net conveyor.

 Detach moulded dough from endless belt.

Baking Section:-
OVEN:-
Oven is one of the important parts of baking industry. For baking, oven used is
F.O. or H.S.D. There are 6 burners in oven, 2 air blowers to remove excess heat
and gases from oven. Each zone has different number of burners (Balanced or
Unbalanced burner).
The oven consists of a wire band moving inside the moving tunnel from both the
sides. The temperature set is different in each zone. The material to be baked is
placed on the wire net conveyor which moves at a definite speed. The baking time
and speed of the wire band is adjusted according to the rpm of die roll and the
temperature profile.
Each of the zones is provided with a damper which is thereto remove moisture
from the biscuit. The damper position can be varied from fully closed to fully open
as per the requirement. The damper is closed in the initial zone for the maximum
moisture retention and is fully open in the last zone for the maximum removal of
the moisture.
The oven is divided into three major parts:
 Puffing Zone: Zone 1 to 2
 Baking Zone: Zone 3to 4
 Coloring Zone: Zone 5to 6

Brief description of each zone is given below:

 Puffing zone(zone 1to 2):-

The leavening agents act a major role in this zone. The steam and other volatile
gasses do arise and increase the volume of the biscuit.
The leavening agents like ammonia and soda do produce CO2, steam & ammonia
which aerates the biscuit. This gives a porous texture by the formation of puffs in
the biscuit. The temperature of the zone is between 160to 240°C.
  Baking zone(zone 3to4):-
This is the zone where the biscuits actually get baked. The temperature of this zone
is between 220-320°C. This is one of the CCP (Critical control point) of BournVita
biscuit. At this point all the chemicals are removed from biscuits & biscuit is safe
for consumption.
The moisture content of biscuit gets reduced to 1.3-2.3% in this zone. At this point
all the chemicals are remove from biscuit & biscuit is safe for consumption.

 Coloring zone(zone 5 to 6):-

This is the zone where the Color of the biscuit is attained. The temperature of this
zone is less than that of the baking zone & retained to 230-180°C.
The color is achieved due to following reactions:-
 Caramelization
 Millard Reaction
Temperature profile:
Zones:- Top Temperature°C
Zone 1 175
Zone 2 230
Zone 3 240
Zone 4 220
Zone 5 180
Zone 6 120

Baking time:-

Baking time of biscuit is different for different varieties which range between 5-
7minutes.For Bournvita biscuit the baking time is 5.30min. After baking the
moisture content of the biscuit is 1.3% to 2.3%.

Cooling of Biscuit:-
Cooling is the most important part of biscuit production. Biscuits coming out of the
oven are too hot, soft & usually very moist so can’t be packed, so they are
transferred to a cooling band. Cooling is mainly done with the help of belt
conveyor & this procedure takes one and half of baking time that is 7.95 minute.
The roof of the cooling area should be at least 15 feet high. Hot air gets trapped on
the top if the roof is not sufficiently high. If possible, at least 2 exhausts should be
provided on the top deck of the cooling conveyor. There should be adequate
number of high speed fans blowing on the cooling conveyors to cool the biscuits.
Cooling is also necessary for sugar rich biscuits, as they are very soft as they leave
the oven and get rigid when cool. There is also an appreciable loss of moisture as
the biscuits cool, and this is beneficial to their quality and shelf life.
Improper cooling of biscuits affects the shelf life of biscuits due to rancidity
problems or high moisture content. Suddenly cooled biscuits create problems of
checking i.e. hairline cracks in biscuits.
Packaging section:-
Packaging section consist of the journey of baked biscuit to finished goods.

Dyno drive stripper

In this section first of all biscuit move ahead from dyno drive to stripper. Stripper
is an important belt which is use to remove defected or over baked biscuit or if we
have to remove dyno drum, we remove stripper first.

Stripper turning table cooling conveyor cooling conveyor2

cooling conveyor3 biscuit transfer

From stripper biscuit moves to turning table than to cooling conveyor 1, then to
turning table 1, then to cooling conveyor 2, then to cooling conveyor 3,then to
biscuit transfer. Function of cooling conveyor is to cool down the biscuit. Cooling
time is 1.5 times the time of oven it is around 7.3 min.

Biscuit transfer stacker web stacker brush stacker roller

From biscuit transfer it goes to stacker web function of stacker web is to match the
position of biscuit with that of the packing table.

Stacker consist of stacker brush and stacker roll that is star wheel. Stackerroll fitted
just above stacker belt(brushes touching biscuits) to control the movement of
biscuits i.e. help to come biscuits one by one. Stacker roll help to align the biscuit
resting vertically.
Stacker roll packing table chutes magazine
carrier chain top transfer multiplier kanghiconveyor 1
conveyor 2 conveyor 3 merging conveyor

From the packing table sizer pick a long row of biscuit and feed it to the feeding
chute. From there it goes to magazine and then to carrier chain feeding wire.In our
packing section there are two sandwich machines and each sandwich machine
consist of 8 feeding chutes with four machines and total 8 machines ie. Machine
no. 11, 12, 13, 14, 15, 16, 17, 18,.from there it moves to multiplier through top
transfer. Multiplier matches the position of biscuits with that of conveyor 1and
move it forward with the help of kanghi . Then it moves to conveyor 2 and 3 and
then to merging table.

Merging table cooling tunnel safe line(metal detector)

packing conveyor

Merging table merge 8 rows from each of two sandwich to 16 and then the biscuit
passes through cooling tunnel to the safe line that is metal detector.

Cooling tunnel consist of four conveyors zones. It works when Oreo biscuit is
produced.

Metal detector is present in the safety line which detects any form of metal in the
biscuit. This is the one of the CCP (critical control point) of plant . Efficiency of
metal detector is checked hourly with the probes of 1.5 mm ferrous, 2 mm
nonferrous and 2.5 mm stainless steel.

After passing through safe line biscuits are moved forward to packing conveyor
1,2,3,4.

packing conveyor conveyor chute packing machine1/2/3/4/5/6

autopusher roller checkware secondary packing

taping palletize ware house

From this packing conveyor sizer feeds the biscuits to feeding conveyor and then
they move ahead to the respective packing machine. There are 6 packing machines,
four of them are producing 10 shells packet, machine no 3 is producing 26 shells
packet and machine no 6 is producing 6 shells packet.
In the packing conveyor chute auto pusher pushes the biscuits ahead and then
infeed chain carries it propeller roller wrap thelaminate over it roller 1androller2
make long seals and cutter roller make cross seal and then it is carried forward by
later chain. Check ware are present to eject overweight or underweight packet.
Then it moves forward on conveyors to secondary packing and then it is manually
packed in a carton that is tertiary packing. Further it is taped and palletized and
then sent to FG warehouse to dispatch.26 shells and 6 shells packets are directly
filled to cartons and outer respectively.

10 shells packing machine pack 110 packet per minute , 26 shells machine packs
65 packs per minute and 6 shells machine packs 114 packets per minutes.

Relative humidity of packaging section is between 45 to 50%.

Temperature of packing Section is between 22 to 25°C.

Packing and production is not the only thing which we take care of we also assure
to our consumer that we are providing good quality product full of nutrient and
having excellent flavor, aroma, taste, texture and appearance. For this we do our
best.

Bournvita biscuit variety:-

Packet Weight(gram) Unit of biscuit

27.9 6
46.5 10
120 26

Oreo biscuit variety:-

Packet Weight(gram) Unit of biscuit

20 2
50 5
60 6
100 10
120 12
150 15
 Quality Assurance of Mondelez:-

Mondelezhas been known for its quality standards. The company is very particular
as far as quality of its product is concerned and to assure that there are no
complaints about its products, the company provides timely training to both the
staff members and workers.

Functions of quality assurance department:

 To check all the quality parameters of the raw materials/ingredients used for the
finished products.
 If there is any deviation in the raw materials supplied from the Mondelez standards
then the Q.A department rejects that particular lot.
 Along with raw material handling Q.A department also checks or controls all
process parameters on shop floor like –biscuit moisture, stack
height,length,width,weight,color,baking etc.
 Maintain packing material (wrapper, polybag, Box) standards as per the
requirement.
 The department carries on time to time checking and control of qualitative
parameter of finished goods.
Laboratory tests are conducted to test the moisture content, ash content, fat content,
acid insoluble ash and fat content of biscuit.

CRQS(consumer relevant quality standards):

Biscuit CRQS0f Bournvita:-

1. Leaf damage: -Clear visible leaf with well define impression of leaf

2. Holes in biscuit due to Bournvita: -No holes shell be present due to Bournvita
granules, clear visibility of granules.
3. Choco bar damage: -Clear visible Choco bar with well-defined impression of all
Choco bar.

4. Sugar crystals: -No sugar crystals shall be visible in the biscuit.

5. Chipping:-Edge of biscuits chipped of due to the damage on the line.

6. Breakage:-Whole biscuit with no checks, cracks or broken pieces.

7. Embrossion:- clear product branding with well-defined impression of all

featured, round shape as opposed to oval.

Biscuit CRQS 0f Oreo:-

1. Mould Impression Branding,Shape

2.Sandwich/Shell Breakage

3. Reversed Sandwich

4. Cream ozing

5. Smearing

6. Wedges

7. Off centered sandwich

8. Edge Chipping/Flaking

Sampling location – every packing machine

sampling plan – 100 biscuit
Frequency check – half hour

Along with this we also make concern about the packing . packing CRQS is also
done , each packet is checked for it’s cut, seal open, slant, silver line, loose,
wrinkle, long seal(8-10mm), cross seal(4-6mm) in a frequency of half hour.We
use high quality of laminate made of low density polythene.
Packet is made air tight by sealing laminate with the help of long seal and cross
seal roller. To ensure that the seal is done perfectly and no laminate is left unsealed
we conduct VLT (vacuum leak test).

VLT is done for each size packet. We pick eight random biscuit packet from each
packing line and keep it inside VLT apparatus at certain pressure for fix time and
then it is check whether air bubbles are forming or not. If air bubbles are forming
then we again check two more time for other eight samples from the same packing
line and again check for air bubbles. Hence if two out of three times air bubbles are
forming then we hold the material from last safe check. Frequency of VLT test is
half hour.

For 10 and 6 shells packet VLT pressure is 150 mm for 10 second and for 26 shells
packet VLT pressure is 300 mm for 10 second.

Apart from this we also consider the appearance of laminate. We check for the
printing of the laminate it should not be double written or blur. We especially focus
on the silver line which is sometimes found in the long seal of the packet. This
silver line should not be more than 3 mm. it specify whether the printing is done
perfectly and every information in the laminate is written at it’s specified position .

In laboratory tests for the bond strength and seal strength of laminate are done.

For cartons , moisture content, length, width, height, weight, bursting strength, and
GSM are checked.

If packaging is not proper then these packets removed manually and collected in a
trays. These are then unwrapped biscuits arranged in trays manually and carried for
repackaging.

Dispatching:

The biscuit are packed in corrugated boxes and sent for the dispatch. A forklift
carries these pallets on which the corrugated boxes are placed. The biscuit boxes
are loaded in a truck and transported to various depose situated at different
 locations . these depots sell these biscuits to various retailers, which further sell the
biscuits in the local market. The shelf life of the biscuits is 12 months or depends
on variety. They are kept in the category of market complaints and

immediate action is taken to improve the quality of biscuit and packaging so that
there is no market complaint.

 Maintain HACCP norms (Hazard Analysis Critical Control Point) in the plant and
conducts audits for further –up.
 Pest management is also done in the whole plant.