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A Summer Training Report on Parle Plant at Varanasi

SUBMITTED BY: RAHUL KUMAR


ENROLL NO.20120366
SECTION- A

SUBMITTED TO:DR. LOKESH UPADHYAY


H.O.D. OF IBMER

CONTENT
1. ACNOWLEDGEMENET
2. INTRODUCTION

3. QUALIT
4. PRODUCTS MANUFACTURED
5. MATERIAL & PROCESS
6. TEMPRATURE
7. INSTRUMENT
8. OVEN & TEMPRATURE
9. HIGHT & WEIGHT
10. PACKING/TEMPRATURE
11. LABORATORY AREA

ACKNOWLEDGEMENT
I hereby put our sincere thanks to one and all. Special thanks go to
HR EXICUTIVE & other staff of PARLE PLANT. Who took out time from
his busy schedule to discuss the intricacies of this Parle plant with us and for his
valuable guidance and support.
RAHUL KUMAR

STUDENT OF
IBMER

INTRODUCTION

IN 1929 a small company by the name of Parle products emerged in British


dominated India. A small factory was setup in the suburbs of Mumbai to
manufacture sweets and toffees. A decade later it was upgraded to manufacture
biscuit as well.
Parle products has been India largest manufacture of
biscuit and confectionary .the company is makers of world largest selling biscuit

PARLE-G and host of other very popular brands like KRAKJACK,MONACO 2020, HAPPY-HAPPY etc.
SINCE 1971 with a 40% a share of the total biscuit
market and 15% share of the total confectionary market in India.
Apart from the factories in
Mumbai and Gorakhpur Parle also has factories in Varanasi in Utter pradesh Parle
product has 2 manufacturing units and 51 units on contract .and Parle G biscuit
share 70% on glucose biscuit of India
Parle products is an Indian private limited company. It owns the famous

biscuit brand Parle-G. As of 2012, it had a 35% dominant share of the


Indian biscuit market.
Mainly in Shree Nath Jee Bakers Pvt. Ltd. Parle plant manufactured biscuit include
20-20 cookies and happy - happy cookies;

Brands
Biscuits
Parle-G, Krack Jack, Monaco, Kreams, Golden Arcs, Parle Marie, Milk Shakti,2020,Happy-Happy, Parle Hide & Seek Bourbon, Parle Hide & Seek Fab, Top, Parle
Gold Star.

Sweet confectionery
Melody, Mango Bite, Poppins, 2 in 1 Eclairs, Mazelo, Kismi Toffee Bar,London
Derry.

Snacks
Monaco Smart Chips, Parle's Wafers, Fulltoss, Parle Namkeens

Since they have been entered at the food competition of Monde Selection in 1971,
the brands have received consistently gold and silver Quality Awards at the World
Quality Selections.

QUALITY
The Parle name symbolize quality nutrition and great taste .hygiene is precursor to
every process at Parle from husking the wheat and melting the sugar to delivering
final products to the supermarket and store shelvesnation wide, Care is taken every
step to ensure the best product to long lasting freshness. Every batch of biscuit and
confectionery are thoroughly checked by expert staff. Using the most modern
quality equipment henceensuring the same perfect quality across the nation and
abroad

PRODUCT MANUFACTURED

Experience a world of happiness with Parle Happy Happy Cookies.


Baked to perfection, these cookies are topped with delicious
choco - chips to give you that never-ending feeling of unbridled
joy. Just open a pack of Parle Happy Happy Choco-Chip Cookies,
pop one in your mouth and feel your senses come alive.

MATERAILIngredientWheat Flour
Sugar
Syrup
RBD Palm Oil
Cocoa Mix
Caramel RT-80
Durk Compound Chips
Salt
Sodium Bicarbonate
Ammonium Bicarbonate
MACP
Soyalasithene
Powder Chocolate Flavour
SMBS
Water
Ammonium Carbonate

180.00kg
70.200kg
5.400ml
63.00kg
27.00kg
1620ml
30.600kg
1 .800kg
0.960kg
1.800kg
20gm
620kg
620gm
30gm
Variable
Variable

MIXING
PROCESS
-

Sugar +
RBD + Soyalasithene + Syrup + Caramel RT-80 + Chocolate
flavour, then rotate Slow for 7 min Dry creaming, then mix the
chemical (NH3 + Soda + Salt) Wet creaming. After 3 min, we have
mix Wheat Flour + Cocoa Mix (Sugar 70.00kg + Cocoa Powder

30.00kg)Mix 360 sec and mix Chocolate chips 30.600kg after


mixing.
(FOR THE 1 BATCH PRODUCT)
(COCOA MIX)----Sugar-70.00kg, Cocoa powder-30.00kg
(SYRUP)---Sugar and Citric Acid mix then make Syrup

WE HAVE CHEACK NOW


Breat Sugar Temp
Syrup Sugar Temp
RBD Temp
Water Temp
Broken Powder Temp
Dough Temp

40-45 0C
35-40 0C
40-45 0C
8-12 0C (summer),
15-20 0C (winter)
______
28-32 0C

ROTARY AREA:INSTRUMENT (1)


(2)
(3)
(4)
(5)
(6)

Dough Tilter
Dough Hopper
Dough Feeder
Metal Detector
Riciprocating
Roller(3 type)-Dye, Rubber, Forceing

(7)
Oven(3 type)-Buffing, Cocking-CCP, Colouring {total 9
type zone}
(8)
Belt (2 type) - Endlens, Pener.

Oven Length(1)
(2)

280m
260m

One time rotted Dye make 465 biscuit


Baking Time:- 5:00 mim

Belt RPM
1 Belt (Endlens) = 960 RPM
2Belt (Pener) = 750 RPM
Dye= 655 RPM
Out of oven biscuit tempreture - 102-105 0C

Biscuit Weight & HeightWeight of 1 Biscuit


St Height of 10 Biscuits
No. of Biscuits in one packet
No. of packet in one polybag
No. of polybag in one C
10 Biscuit St. height

5.0 gm
67-69 mm
8 pack
24
67-69 mm

1 pally bag with 1c box weight


Packet 1 pally bag weight

6.550 kg
985gms

CCP ZONE 3
Upper critical limit- 290 C0
Lower critical limit- 280 C0

DEMPER (maintain the temperature)


(1)
(2)
(3)
(4)
(5)

0 C0
0 C0
20 C0
40 C0
50 C0 etc.

PACKING1 Pack- 8 biscuit


1 Pally bag- 24 packs
1c Box- 6 pally bag
1c Box- 144 pack

PACKING MACHINE TEMPRETURE-(MLT PACK)Bottom Heater H1- 210 C0


Bottom Heater H2- 195 C0
Cutter Heater Top- 134 C0
Cutter Heater Bottom- 131 C0

Speed Max- 80 PPM

Coding on wrapper for Happy-Happy cookies

Parameter
PKD.
Batch

Wrapper
2/4/14
VA 2AB

Polybag
2/4/14
VA 2AB

C box
2/4/14
VA 2AB

Plant No.1
Drive RPM vs. Baking Time
Drive RPM
570
591
600
615
620
642
650
660
672
684
702
720

Baking Time (min)


7.35
7.15
7.07
7.05
7.00
7.41
7.35
6.30
6.25
6.17
6.09
5.58

Coding Machines Reading


Pressure (mbar)

2997-3005

Pump Speed (rpm)

1603

Actual BFT (s)

100

Target BFT (s)

96

Ink Temperature (0C)

41

Time for printing one role


speed)

45 min. (with 50

No. of packet in one role

14360

Laboratory Area
Testing For Butter and Cashew Cookies

Wheat Flour testing


RBD testing
Milk Powder testing
Cashew testing

Sugar testing
Butter testing
Soyalasithene testing
Fenamul-DL testing
Flavour-1 NN testing
Butter Flavour-2 testing
Syrup testing
Ammonia testing
Soda testing
Salt testing
Citric Acid testing
Broken testing

Testing For Happy-Happy Cookies

Dark Compound Chips testing


Caramel RT-80 testing
Coca mix powder testing
Chocolate flavour powder testing

Test for Wheat flour1. Moisture (10 gm)


2. Alcohol acidity (5 gm)
3. Sedimentation Value (3.2 gm)
4. Sieve (50 or 100 gm)
5. Water Absorption Power (25 gm)
6. Total Ash content (15 gm)

7. Acid Insoluble Ash (200 gm)


8. pH (200 gm)
9. Protein percentage
10. Germ oil Test
11. Drink Test

Test for RBD palm oil1. Free fatty acid (20 gm)
2. Peroxide value (5 gm)
3. Iodine value (0.5 gm)
4. Slip melting point (10 mm)
5. Antioxidant (5 ml)
6. Temperature
7. Smell and Drink Test

Test for Milk powder1. Moisture (10 gm)


2. Alcoholic acidity (20 gm)
3. Total ash (15 gm)
4. Fat percentage (10 gm)
5. Protein (5 gm)

6. Bulk density (25 gm)


7. Adultration ( starch, urea, sucrose, ammonium compound,
soyalasithene,
NH4SO4, NaCl)
8. Dry and drink test

Test for Cashew1. Moisture (5 gm)


2. Acidity (10 gm)
3. Fat (10gm)

Test for Sugar1. Sucrose percentage (0.5 gm)


2. Sulphur dioxide (1 gm)
3. Physical test

Butter-Test for
1. Moisture (5 gm)
2. Acidity (20 gm)
3. Fat (10 gm)
4. Salt percentage (5 gm)

Test for Soyalasithene and Fenamul1. Acid value (20 gm)


Test for Flavour 1 + 2-

1.Specific gravity (25 gm)

Test for Syrup1. Alcoholic acidity (5 gm)


2. Inversion (5 gm)
3. Brix

Test for Ammonia and Soda1. Purity (2 gm)

Test for Salt1. Sand percentage (2 gm)

Test for Citric acid1. Purity (1 gm)

Test for Dark compound chips1. Counting

Moisture

Take 10 gm. Maida sample in a petridish and put


petridish in hot air oven maintain at 1300C to 1330C for
1.5 hrs.

Cool in the desiccator and weight it again put in the


hot air oven under same condition for 15 min.
(continue it till the constant weight is achieved).

Cool in the desiccator and weight it.

% of moisture = wt. of sample taken - wt. of dried


sample
x 100
wt. of sample

Standard = 13 % max

Sieve Test

Take 100 gm. Maida sample in 80 mesh (180 micron) for


sieving.

Sieve it properly.

Take out the retention material and weight it.

% of retention = wt. of material retained on sieve


100
wt. of Maida sample

Standard = 0.3 % max

Total Ash

Take 15 gm. Maida in silica crucible

Put into muffle furnace and temperature maintain 600 +_


100C for 6 hrs.

Cool in a desiccators and weight it and repeat the same


procedure till the
constant weight is
achieved.

% of total ash = wt. of ash obtained


(100-M) x wt. of sample

X 100

Standard = 1.0 % max

Antioxidant Test

Take 5 ml. Melted Vanaspati in a test tube

Add 10 ml. Methanol and shake well for 5 min.

Stand it for 5 min.

Withdraw 2 ml. Of upper layer and 2 ml. Di-methyl amine

Shake for 2 min.

If pink colour appears then antioxidant positive

Sedimentation value

Take 3.2 gm. Maida sieving through 100 mesh in


graduated cylinder with stopper

Add 50 ml. Bromo phenol blue indicator and Put on


sedimentation shaker for 5 min.

Remove the cylinder and add 25 ml. Isopropyl lactic acid


and put on sedimentation shaker for 5 min.

Remove the cylinder and keep it in upright position for 5


min.

Note the reading in ml.

Standard = 19 23 ml

Peroxide value

Take 5 gm. RBD in a Idometric flask

Add 30 ml. Acetic acid chloroform and dissolved it


properly

Add 0.5 ml of freshly saturated KI solution

Add some drop of starch indicator and stand it exactly 1


min.

Add 30 ml of distilled water and titrate with 0.01 N


Na2S2O3 solution.

End point colour disappear

Carry out the blank it.

P.V. = 1000 x ( S-B ) x N


W
S= Sample, B= Blank, N= Normality, W= Weight of RBD
Standard = 1.25 Meq./kg. max

Free fatty acid

Take 20 gm. Vanaspati in a conical flask

Add 50 ml neutral Ethyl alcohol

Put it on hot plate for 5 min.

Titrate with 0.05 N NaOH

End point pink colour appears

% of free fatty acid = 25.5 x N x V


W

Standard = 0.1 % max