MANUFACTURING & PROCESSING OF PARLE-G BISCUITS

SUBMITTED BY: MRIDULA BHANDARI

CONTENTS Introduction Logo Products range Overview: Parle Pvt. Ltd, Rudrapur Working Structure : 5’S Policy Production Unit Flow Chart Inventory management Raw materials Process layout of Parle-G biscuits

CONTENTS (CONTD.) Coding General data for Parle-G HACCP GMP Conclusion

INTRODUCTION1. Industry : Food2. Founded : 19293. Headquarter : Vile Parle (East), Mumbai4. Parent : Chauhan family5. Products : Biscuits, Snacks &

Confectionary6. Revenue : $977.24M7. Net income : $39.55M

LOGO

Red color denotes hunger & health White color denotes purity & goodwill.

PRODUCTS RANGE The company is associated with the

manufacturing of a wide variety of biscuits and confectionary items:

Biscuits: Parle-G, Monaco, Krackjack, Hide & Seek, Golden arcs, Golden kreams, Parle 20-20.

Confectionery : Poppins, Melody, Mango bite, Eclairs, Kismi bar

The Pantnagar plant is involved in manufacture of Parle-G, 20-20, Happy-Happy, Orange Kreams.

OVERVIEW: PARLE PVT. LTD. , RUDRAPUR

Established in 2005 over a vast area of 13 acres Boasts Asia’s largest oven Average production is 5,000 metric ton per month 56 officials and 910 workers There are 3 plants in the unit as follows:1) P1- Cookies (Happy-Happy, 20-20)2) P2 - Parle-G3) P3 - Orange kream biscuits

WORKING STRUCTURE: 5’S POLICY

5’S Policy

Seiri- Reorganization Seiton -Neatness Seiso - Cleanliness Seiketshu - Standardisation Shitsuke – Discipline

PRODUCTION UNIT FLOWCHART

Raw material section 

Mixing section 

Rotary and moulding section 

Baking section 

Cooling and stacking section 

Packaging and dispatch section

INVENTORY MANAGEMENT Inventory management is primarily about

specifying the size and placement of stocked goods.

Required at different locations within a facility or within multiple locations of a supply network.

To protect the regular and planned course of production.

It is about knowing where all your stock is and ensuring everything is accounted for at any given time.

INVENTORY CHECKPOINTS FOR RAW MATERIAL STORES FSSAI Lic. No. should be mentioned in invoice copy

as well as in their bags and boxes of each and every materials.

Food grade statement should be mentioned in invoice copy.

COA report are attached with every consignment and every report should be clear as per the norms of FSSAI

Manufacturing and expiry date should be mentioned. All materials loaded/unloaded in neat and clean

area.

INVENTORY CHECKPOINTS FOR RAW MATERIAL STORES (CONTD.) All RM/PM issued as per the FIFO/FEFO for

maintain better inventory storage system. Covering all RM/PM for reducing contamination

and maintain hygiene of the material products. Scrap materials left-ups as per the given time

duration. Identification boards are updated according to

RM/PM for Maintain FEFO/ FIFO of the material vehicle verification as per verification list.

FIFO - First In First Out FEFO- First Expiry First Out

RAW MATERIALS Maida (wheat flour) Finely milled wheat flour Becomes cohesive, elastic and gas

retenting when hydrated and kneaded. In presence of water forms gluten

which is responsible for above properties.

Acts as a structure builder.

RAW MATERIALS (CONTD.) Sugar Responsible for structure and hardness in

short dough biscuits Aids surface coloration Enzyme carrier

Invert Syrup Prevents surface crystallization Gives colour and helps in moisture retention

RAW MATERIALS (CONTD.) Salt Modifies other flavours Affects the rheology of dough and

improves the dough crumb colour.

Water Acts as solvent to form dough Acts as a leavening agent and helps in

expansion.

RAW MATERIALS (CONTD.) Skimmed milk powder (SMP) Provides nutrients to product Used as a minor dough ingredient to give

subtle flavour and textural improvements to aid surface cooling.

Ammonium bicarbonate (ABC) Leavening agent Maintains the stack height of biscuits.

RAW MATERIALS (CONTD.) Sodium bicarbonate Self contained leavening agent Adjusts the acidity of dough and taste of

biscuit Puffing activity

Sodium meta bisulphate (SMBS) Used in very small quantities as a

preservative and to modify gluten quality chemically

RAW MATERIALS (CONTD.) Lecithin Acts as an natural emulsifier

Finamul Is an artificial emulsifier

Vanilla flavour Artificial flavour induces the characteristics

flavour into the biscuits

RAW MATERIALS (CONTD.) Parle Flavour Mix It is added in Parle G dough. It has

maturation time of 1 month so is used 1 month after the date of manufacture.

Propylene Glycol Mixed with Parle flavour in PFM tank to

make flavour.

PROCESS LAYOUT OF PARLE BISCUITS

Parle-G biscuit plant consists of different units to perform various works, they are as follows-

Raw materials storage Maida sugar section Mixing unit Rotary unit Oven Cooling Packaging unit

1. RAW MATERIALS STORAGES.NO.

COMMODITY HOLDING TIME

STORAGE CONDITIONS

1. Maida 15 days Room temperature

2. RBD 1 Month In silo at 40-45°c

3. Sugar 1 Year Room temperature

4. SMBS 9 Months Cool and dry place

5. SMP 9 Months Cool and dry place

6. SBC 3 Years cool and dry place

7. ABC 9 Months Room temperature

1. RAW MATERIALS STORAGE (CONTD.)

S.NO.

COMMODITY

HOLDING TIME

STORAGE CONDITIONS

8. Salt 2 Years Cool and dry place away from sunlight

9. MACP 2 Years Cool and dry place away from sunlight

10. Finamul P-4107 1 Year Cool and dry place at room temperature

11. PFM 1 Year At room temperature and dry place away from sunlight

12. Citric acid 2 Years Cool and dry place at room temperature

13. Lecithin 1 Year Dry place away from sunlight

14. Orange flavor 1 Year At room temperature cool and dry place away from sunlight

1. RAW MATERIALS STORAGE (CONTD.)

S.NO.

COMMODITY HOLDING TIME

STORAGE CONDITIONS

15. Cardamom flavor 1 Year Cool and dry place away from sunlight

16. Liq.vanilla flavor 1 Year Cool and dry place away from sunlight

17. Condensed milk 1 Year At room temperature cool and dry place away from sunlight

18. Sunset yellow 5 Years At room temperature cool and dry place away from sunlight

19. Propylene glycol 2 Years At room temperature

20. Ethyl vanillin powder 5 Years Cool and dry place away from sunlight

21. Vanillin powder 5 Years Cool and dry place away from sunlight

2. MAIDA SUGAR SECTION

Both maida and sugar are stored in large vertical tank. RBD is stored in vertical silo.

3. MIXING UNIT

Powder vessel - Receives 110kg of maida per batch from maida service tank through pipelines.

Creamer vessel - Receives Ghee, Powdered sugar, skim milk, Palm oil from RBD through pipeline at temperature 40-45°C.

Powdered sugar is passed through vessel and SMP is provided to the creamer vessel.

Finamul is used as emulsifier mixed with Palm oil. CV agitator is attached to the vessel to agitate the

ingredients properly.

3. MIXING UNIT (CONTD.) Liquid vessel - Receives Soda, Salt, Ammonia, Sugar

Syrup, PFM (Parle flavour mix) ,and water. SSA is provided to vessel. Temperature of sugar syrup should be about 42°C.

Stephan Mixer - An ideal component to fully automatically feed the downstream make up equipment for biscuits.

There are two types of motor attached to mix all material - Baffle motor and Mixer motor.

Rotation is about 600-700 revolutions. The operation divided into four phases: loading, mixing,

kneading and discharging, leads to a delicate crumb and an extremely machine able dough.

CREAMER VESSEL LIQUID VESSEL

STEPHAN MIXER

4. ROTARY UNIT

Has rotary blades which rotates and mix the dough to its final stage.

Dough temperature is about 33.5°C. Roller rolls the dough and cutting knife helps in cutting the

dough so that dough should pass from roller die equivalently and each cup of die receives appropriate amount of dough to form biscuits.

Roller Die drum has 12 cups in circle and 31 cups in length of the die drum.

Die gives the shape and size to biscuits and imprints the name of product i.e. Parle-G on top of the biscuit.

After these biscuits are passed on to rotary belt they are conveyed up to oven and are passed on the wire band belt in oven.

5. OVEN

Propane gas is used as fuel. Width of the oven is 54.5 inches and its length is 728 ft.

Total length of oven is divided in three zones i.e Puffing zone 30% of total length. Baking zone 40% of total length. Colouring zone 30% of total length. There are damper plates at each zone of oven

whose opening and closing maintain the steam inside the oven.

5. OVEN (CONTD.) In first three zones damper plates are 20% to 30% open

to maintain the steam in oven for better puffing of biscuits. In zones 4, 5, 6 & 7, the damper plate is open about 40% to 60%. Here the biscuits are baked and temperature is also high. In last three zones i.e.8, 9 &10, the damper plates are almost totally opened to release all steam from the oven.

Zones number 6, 7&8 are known as CCP zone. Their minimum temperature is 230ºC-320ºC.

It is most important zone among all other zones because it maintains shelf life of the biscuits.

CCP should be monitored time to time to ensure the receiving of desired temperature range.

BAKING PROFILE

Zone 1 Zone 2

Zone 3

Zone 4

Zone 5

Zone 6

Zone 7

Zone 8

Zone 9

Zone 10

Upper 220±20

240±20

260±20

280±20

290±20

300±20

275±20

245±20

240±20

220±20

Bottom

200±20

230±20

250±20

270±20

285±20

290±20

250±20

230±20

235±20

190±20

CHANGES DURING BAKING

Evolution and expansion of gases Coagulation of gluten and gelatinization of starch Partial dehydration from evaporation of water Development of flavours Change of colour due to Mallard browning

between gluten protein with milk and reducing sugars as well as other chemical change

Crust formation from surface hydration Crust darkening from Mallard browning and

caramelized sugar

6. COOLING

The hot baked biscuits from oven are conveyed through cooling conveying belt for cooling of biscuits.

The total travel of the cooling conveyor is 1.5 times of the oven length.

It is done for 5-7 minutes so that biscuits become cool and all the moisture gets evaporated.

A metal detector is placed after cooling to avoid any metallic contamination.

7. PACKAGING UNIT

Sealing machine - It is used to seal poly pack of biscuits.

Taping machine - It is used to seal the cartons. Multipack machine - It is a fully computerized

machine to pack packets of different weights according to requirements.

Packaging material - Two types of materials are generally used.

1. BOPP (Biaxially Oriented Polypropylene) films as primary packing material.

2. Corrugated fibre boards as secondary packing material.

7. PACKAGING UNIT (CONTD.) The conveyor continues to move to counting table

where biscuits are counted & then to staking table at which biscuits are packed in very orderly manner.

From staking table, the biscuits are moved on conveyor to multi pack wrapping machine.

During sealing of packet, the temperature of upper jaw and lower jaw is 140ºC.

Parle-G are packed into poly bags & sent to sealing machine where it is sealed, then to corrugated box section where poly bags are placed manually and box is passed through at a taping machine where the boxes are tapped.

SEALING MACHINE TAPING MACHINE

MULTIPACK MACHINE

CODING Coding includes PKD (month & year), Batch

number (PN i.e. Pantnagar, date, shift, B) Short date coding - Parle –G (70g) Long date coding - Parle-G (140g) Note - There should be same coding in

box, packet, coupon and poly bag. During offline coding the wrapper font size

coding should be of same height not less than 2 mm.

GENERAL DATA FOR PARLE-G

Weight of baked biscuit = 5.5-5.10gm Number of biscuits in 1 packet (45gm) = 9 Weight of baked biscuit + weight of

packet = 46.45gm Length of biscuit = 55 mm Width of biscuit = 36mm Stack height = 105-107mm Baking time = 3.30 min

HACCP Stands for Hazard Analysis and Critical Control

Point. It is a systematic preventive approach to food

safety from biological, chemical, and physical hazards in production processes.

Critical Control Points (1) Sugar syrup filter press (2) Maida sifter sieves (3) Metal detector – For ferrous =1.5mm For non-ferrous=2.0mm For S.S. = 2.5mm

GMP (GOOD MANUFACTURING PRACTICES)

GMP Is a production and testing practice to ensure a quality product. It covers following parts –

1. SOPs (Standard Operating Procedures) – Step by step procedures Product consistencey & safety Legal requirements

2. Personnel – Behaviour & dress Smoking, eating & drinking are prohibited Aprons, hair covering, no jewellery Proper hand washing

3. Good Housekeeping Operational Storage area Administrative

CONCLUSIONS Practical part was seen i.e. from procurement

of raw material to the final dispatch.

Proper process control and quality checks were maintained.

Protocols followed in the entire process.

Allotment of responsibilities and authorities for food safety and management system.

THANK YOU…