Operation Management Project : Cadbury

Process Layout.

Presented to :- Professor Ranjit Roy Ghatak; IMI Bhubaneswar

Made By:-
 Vibhor Agarwal
 Nishkarsh Agarwal
 Ajit Maurya
 Prerna Mishra
 Nidhi Kesari kumara
 Varun Bisht
 Aditi
Table of Contents
Contents……………………………………………………Page No.
1. Introduction………………………………………… 3
2. Process Layout……………………………………… 4
3. Problem and findings………………………………
4. Bibliography*
Introduction
Cadbury, formerly Cadbury's, is a British multinational confectionery company wholly owned by
Mondelez International (originally Kraft Foods) since 2010. It is the second-largest
confectionery brand in the world after Wrigley's. Cadbury is internationally headquartered in
Uxbridge, West London, and operates in more than 50 countries worldwide. It is famous for its
Dairy Milk chocolate, the Creme Egg and Roses selection box, and many other confectionery
products. One of the best-known British brands, in 2013 The Daily Telegraph named Cadbury
among Britain's most successful exports.
Cadbury was established in Birmingham, England in 1824, by John Cadbury who sold tea,
coffee and drinking chocolate. Cadbury developed the business with his brother Benjamin,
followed by his sons Richard and George. George developed the Bournville estate, a model
village designed to give the company's workers improved living conditions. Dairy Milk
chocolate, introduced in 1905, used a higher proportion of milk within the recipe compared with
rival products. By 1914, the chocolate was the company's best-selling product. Cadbury,
alongside Rowntree's and Fry, were the big three British confectionery manufacturers throughout
much of the nineteenth and twentieth centuries.
Major chocolate brands produced by Cadbury include the bars Dairy Milk, Crunchie, Caramel,
Wispa, Boost, Picnic, Flake, Curly Wurly, Chomp, and Fudge; chocolate Buttons; the boxed
chocolate brand Milk Tray; and the twist-wrapped chocolates Heroes.
As well as Cadbury's chocolate, the company also owns Maynards and Halls, and is associated
with several types of confectionery including former Trebor and Bassett's brands or products
such as Liquorice Allsorts, Jelly Babies, Flumps, Mints, Black Jack chews, Trident gum, and
Softmints.
Process Layout
Process layout the process followed at Cadbury India is categorized under line flow. The
company can come under make to order because it produces goods, which have a day-to-day
basis demand. So, it comes under make to stock and maintains some amount of inventory but not
a larger amount because its goods are perishable and have a certain expiry date.
Cadbury has a product portfolio, which includes chocolates, beverages, biscuits, candies and
gums. Its major production of chocolates undergoes a long process, which starts with the cocoa
bean. It is the heart of the sweetest delicacy in the world, which is actually bitter. During the 18th
Century, people only used to eat the sweetish flesh of the cocoa fruit. It has also been used as a
form of currency. There are two basic types of cocoa named Criollo and Forastero cocoas. The
seeds of the Criollo cocoa are of finer quality and are thus used in high quality chocolates
whereas 90% of the world crop accounts for Forastero cocoa.
The basic process of chocolate making in India:-
1. Harvesting: - Firstly, the cocoa beans after harvesting, is treated to prevent the beans from
rotting. The fruit is opened at fermentation sites or at any of the collecting points.
2. Fermentation: - The technique for the fermentation process depends on region to region and
is thus decisive regarding the production of high quality raw cocoa.
3. Drying: - The cocoa beans are still not dry enough and contain about 60% water in them. In
order to soak this water, the beans are spread out on the ground or on mats under the sun.
4. Cleaning:- After the beans are dry enough, they are thoroughly cleaned through sieves and
also by brushing. Further, with the help of powerful vacuum equipment, the last vestiges of
wood, sand and the finest dust is extracted.
5. Roasting:- This entire process is carried out automatically during which the
temperature reaches 1300C in the 10 feet high furnaces. The roasting process is performed
to develop the aroma.
6. Crushing and shelling:- With help of the crushing machine, the roasted beans are broken
into medium sized pieces.
7. Blending:- In order to process special recipes, the crushed beans are weighed and blended.
This is a secret of every chocolate factory that how the different types of cocoa are mixed and in
particularly what ratio.
8. Grinding:- Grinding is basically done to develop the cocoa paste. The crushed cocoa beans
are brought onto rollers where they are processed into a fine paste. This paste is a resultant of the
heat generated and the friction which causes the cocoa butter in the beans to melt giving out the
liquid mixture. The production process at this point is divided into two ways which meet soon
after they are done with their respective paths. One way, a part of the cocoa paste is taken to
large presses in order to extract the cocoa butter while the other way, the other part of the paste is
blended and refined during which some butter is added to the mixture.
9. Cocoa butter: - Cocoa butter is an essential ingredient for chocolates because it is not only a
part of every recipe but it also gives chocolates its fine structure beautiful shine and delicate,
gorgeous glaze.
10. Cocoa powder: - After the butter is extracted from the paste through large presses, cocoa
cakes are left which contain about 10-20% proportion of fat which further depends on the
intensity of compression. These cakes are mashed again and properly sifted in several stages
which results into cocoa powder. A dark and very strong aromatic powder which can be used for
preparation of excellent and delicious drinks known as cocoa. The four basic ingredients for
making chocolate are cocoa paste, cocoa butter, sugar and milk. Using these ingredients and
blending them according to the recipe to be prepared, three types of chocolate can be obtained
which form the basis of ever product assortment.
These are:-
 Kneading
 Rolling
 Conching

Problems and findings

Packaging problem
In 2003 when they decided to upgrade their packaging line for large pieces line, large pieces are
the company's range of 19 different chocolate bars than CHH Packaging Systems offered the
company a flexible, upgradeable solution for the packaging of all of the 19 different formats.

Worm Controversy

On October 2003, just a month before Diwali, the Food and Drug Administration Commissioner
received complaints about infestation in two bars of Cadbury Dairy Milk

In defense, Cadbury issued a statement that the infestation was not possible at the
manufacturing stage and poor storage at the retailers was the most likely cause of the reported
case of worms. Then Cadbury came up with new ‘purity sealed’ packaging and intense
communications program, like advertisement of Amitab Bachan.
Pigging process
Whenever, some proportion of chocolate remain in the pipeline. They use pigging process to
recover all the significant proportion of the substance. Plus, the product they recover is
perfectly good and usable.

Hazard Analysis Critical Control Points (HACCP)

Cadbury uses a system called Hazard Analysis Critical Control Points (HACCP). This helps to
identify what could go wrong in the production process (e.g. biological, physical and chemical
hazards), and to put in place strict quality control checks called critical control points (CCPs) at
key production stages that make sure that the product is safe

Bibliography
References were taken from the following sources

 Cadbury Wikipedia page https://en.wikipedia.org/wiki/Cadbury

 Data collected from Mr. ______________ who works with Cadbury (Gwalior)
 References were taken from