1

Contents

 Aknowledgement

 About ‘Parle G Biscuits Pvt. Ltd.’

 Company profile
 Products range

 About Biscuits
 Classification of biscuits
 Analysis of biscuits

 Brief Description & Uses Of Raw Material

 Processing Of Biscuits
 process manufacturing of glucose biscuits
 digramatic representation

 process Layout Of Parle Biscuits

 raw material storage
 mixing unit
 oven
 cooling:
 packing

 Intended Use Of ‘Parle G’ Biscuits

 Important Details About Raw Materials

 Misslanious

 Wastages

 Specification Of Finished Biscuits

 Factors Affecting Processing Of Biscuits

  Conclusion

AKNOWLEDGEMENT

I express my sincere gratitude towards

‘Mr. S. Panday’ (Manager, parle pantanagar plant)
that enables me inside into the biscuit industry and
without those support this training experience
would not have been possible.

I am extremely grateful to ‘Mr .Sanjay Yadav’

(Production Manager) and ‘ Mr. Rohit Gupta’
(quality assurance incharge) for their consistent
support and guidance. Also I am grately thankfull
to ‘Mr. Shishir’ (HR) and ‘ Mr. Sonu Dhimaan’
(production department) for their help and
valuable suggestions.

Beside this, I heartly wish to express my

sincere thanks to ‘Mr. Manavendra Singh’ (mixing
incharge), ‘Mr. Ashok Arya’ (production) and the
entire management staff, workers and all employee
team of the plant, for their significant contribution
towards the completion of the training and without
whose support this fantastic and knowledgeful
training experience would not have been possible.

Saurabh Kumar Shukla

 About ‘Parle G Biscuits Pvt. Ltd.’

Company profile

The company ‘Parle G Biscuits Pvt. Ltd.’ set up in 1929, the first
Indian company to manufacture biscuits and confectionary in the
country. Many of parle products , biscuits and confectionary are market
leaders in their category. One of its major variety Parle G has been
conferred with a prestigious distintion of being the world largest selling
biscuits. With a 40% share in the total biscuits market , a large no. of
manufacturing units in the biscuits industry, the company enjoys a world-
class reputation and the ‘Parle’ brand symbolizes quality, health and good
taste for its products.

Products range The company is associated with the manufacturing of a

wide varity of biscuits and confectionary items;

 Biscuits: Parle- G ,Atta-G , Magix , Manaco, Krackjack , Hide$Seek

Manaco , Fun center , Sixer, Nimkin , Digestive Marie.

 Confectionary: Poppins , Melody , Mango Bite , Kismi Toffee

Bar ,Chox, Rolacola , Toffee, Orange Candy .

Among Parle G Biscuits varieties, parle g and atta g comprises the

glucose biscuits. The pantnagar plant location of the company is involved
with the manufacturing of the glucose biscuits ‘parle G’ and cream biscuit
‘creams orange.’
 Introduction about biscuits
Biscuits are chemically leavened and baked product made
principally from flour, suger and fat. They typically have a moisture
content of less than 4% and when packed in moisture proof container has a
long shelf life, perhaps 6 month or more.
The use of biscuits is more and common in homes due to there ready to eat
characteristics. The appeal to the customer is determined by the appearance
and the eating quality. They are made in various shape and size and after
baking may be coated with chocolate, sandwiched with a fat based filling or
other pleasantly flavored additions.

Classification of biscuits
a) Depending on texture and hardness ,change in shape of oven the
extensibility of dough or various dough is handled prior to biscuit
formation.

i. Hard dough biscuit :

it has high water and relatively low fat content .the dough is
tough and extensible. They exhibit viscoelastic properties similar to
bread dough because of the three-dimensional gluten network of flour
protein.

ii. Soft dough biscuit :

They contain much less water and relatively high level of fat
and sugar. The dough is short and exhibit very low extensible
character. Soft dough coheres under pressure but has a short fracture
under tension & very little dough development takes place during
mixing.
b) Sweet
In sweet biscuits, the fat and suger level are generally high .
The variety provides very short bite, sweet taste and flavor. It is
depending of relative proportion of fat and suger. Eg. Glucose biscuits

c) Semi-Sweet
Semisweet biscuit have a low level of sweetness. The product is hard
in texture and low in fat. eg. marie

d) Crackers
They showing typical type of flaky inner structer formed due to
specific processing methaodologies . These can be fermented and non
fermented and non fermented type eg. Snacks

e) Cookies
Cookies product are salty in bite compared to the sweet. They
may enriched by incorporation of nuts, dry fruits, chocolate etc. and have
high suger and fat in comparison to sweet.

Glucose biscuits

These biscuit contain reletively more fat and suger content and fall
under the category of sweet biscuits. The suger used mainly in the form of
glucose and that’s why it is called glucose biscuits.
They form healthy diet and a good source of energy and are economically
cheaper than other variety of biscuits. A majority around 65% of the total
biscuits manufactured in India are glucose biscuits.
 Analysis Of Biscuits

Glucose Biscuits

Weight per biscuit 5.50 gm

Dimention of biscuits 55*36*75

Colour of biscuits golden brown

pH 6.5 approx

Stack height 7.5 mm

Biscuits are small baked product made

principally from flour, suger, and fat. They
Discription have moisture content of less than 2.0% and
when packed in moisture proof containers
have a long shelf life perhaps 5 months or
more.

Variety Gluco biscuits

Size 56*36*75
Taste Sweet
Design Rectangular with
impression
0f Parle-g
Specification Bite Sime hard
Color Golden brown
Weight 88gm for 16 baked biscuits
Packet size 75gm, 100gm, 1kg
polybags,
2kg jar
Stack height- above 118 –below 122mm
of
16 biscuits
S.N. Ingridients Quantity
Per
Batch
1 Maida 110 kg

2 Suger 33 kg

3 S.M.P. 980 gm

4 Salt 1200gm

5 Soda 350 gm

6 S.M.B.S. 20 gm

7 A.B.C. 900 gm

8 Lecithin 2 liter

9 P.F.M. 195 ml

10 Water 10 kg

11 vanaspati 21.1 kg

12 Invert sugar 11 liter

1. Maida
It is the ingridient added in the largest ammount in the preperation
of biscuit dough.
Wheat flour has a unique property to form gluten ( glutenin +
gladin). This glutin entrops CO2 (carbon di oxide) released by leavning
agents and get incorporated in dough which escapes during baking.
Thus it expends the product. It is principally responsible for structure
and texture of biscuits.

2. Suger
It gives sweet taste to the biscuits. It is responsible for structer
and hardness in short dough biscuits due to crysallization formation.
Apart form that it also in colour development due to ceremelization. It
also has moisture retaining properties.

3. S.M.P.
It provide nutrient to the product and gives liquid media for dough
formation. It also add fat, salt, vitamins and some enzymes to the biscuits. It
also inhibits the effect of acid.

4. Salt
It inhance flavour and sourness of acid. It effects rheology of dough and
improve color by action of glutin. Increse in salt concentration length in
mixing time.

5. Sodium bi carbonate
It is used as a leavening agent. Leavening is a process of
incresing the area of dough by creating small sacs of CO2 . It is used to
control the acidity of dough.

6. S.M.B.S
It is a preservative used in biscuits in very small quantity. It causes
gluten to become more extencible and less elastic and therefore reduce the
shrinkage of dough pieces during baking .
7. A.B.C.(ammonium bi carbonate)
It is also used as a leavining agent which discomposes complete when
heated, breakning down.

8. Lecithin
It is an extract from soy and act as an emulsifier used for binding of
fat and water molecole. It improve moisture retention and it effect at very
low concentration and does not allow to seperation of water and fat during
baking , Thereby preventing the crust formation.

9. P.F.M.
it gives parle g ,it gives cheracterstic flavour and aroma.

10.Fat / Vanaspati
it forms a layer over the flour particles product a tender texture to
the finished product . it mains function is shorten to gluten strength and
allow greater expentionof product during proffingit works as atenderising
agent ,during mixing it intraps air to theincorporation of other ingradients
to finished productduring baking it become melt and release air bubbles
which contribute to the leavining actionof baking powder and expend the
steam .melted shortening are deposited around the cell wall of
coagulating structure to provide a tenderize effect and lubericate the
texture .it also prevents hardening of biscuit during and after baking .

11.Invert Suger
it made by the hydrolysis of sucroose to glucose and fructose .the
process is known as invertionit prevents thecrystelisation of suger and
resistant to microbiol spoilage due to its low water activity.it also helps in
moisture retention .at high temprature ,it easily undergoes browning
reaction. Thus giving color and flavour to the biscuits.

================================

Processing of Biscuits
 Processing of the biscuit involve these steps-

1. Mixing of raw materials

2. Rotary molding of dough
3. Baking process in oven
4. Cooling of biscuits
5. Packeging and storage

Process manufacturing of glucose biscuits

Handling & material of ingridients

Mixing of the ingredients

Rotary molding of biscuits

Baking of biscuits

Cooling

Packaging & Storage

PROCESSING OF BISCUITS {digramatic representation}

Suger flour l.marvo water syrup marvo
sddduger

Mixer

( all the raw materials mixed here)

Mixed product known as dough

Send to rotary
Rotary oven

Cooling conveyor

Stacker

Packaging

Ready to Eat

PROCESS LAYOUT OF PARLE BISCUITS

Procedure:-
First of all Plants of Parle Biscuits Pvt. Ltd buys raw materials
from the various suppliers and stored them into the store room. These raw
materials are then sent to laboratory for testing and after testing only then
these are used for manufacturing Parle G biscuits.
For the production of Parle G Biscuits the whole plant consists of different
units to perform various works. Parle Biscuit plant is divided into different
sections, they are as follows:-
1. Raw Material Storage
2. Maida Sugar Section
3. Mixing Unit
4. Rotary Unit
5. Oven
6. Packing Unit

Raw Material Storage:-

Each industrial plant should have an area for raw material storage. In
these storage areas, the raw materials are kept until they are used for the
production of desired finish product. For the production of Parle-G Biscuits
a variety of raw materials are required such as Maida, Sugar, Sugar Syrup,
Vanaspati (Ghee), etc.

In Maida Sugar Section, both Maida and sugar are stored in large
vertical tank. RBD (Vanaspati) is stored in vertical silo. These storage areas
should be free from moisture, water logging, direct sun light, insects, and
rodents, so to keep the material safe before it is used.

Mixing Unit:-
 In the production of biscuits this Mixing unit is most important part of
total production area. This unit consists of various vessels or mixers to
perform mixing work in a measurable way for different ingredients used in
biscuits production:-

 POWDER VESSEL
 LIQUID VESSEL
 CREAM VESSEL
 STEPHEN MIXER

1. POWDER VESSEL:-

Powder vessel receives Maida from Maida Service tank through

pipelines. This vessel receives 110 kg of Maida per batch. Moisture content
in Maida is about 13% (12±1).

2. CREAMER VESSEL:-

Creamer vessel receives three ingredient i.e. Ghee, Powered Sugar,

Solid Milk powdered. 20.900kg Ghee per batch is supplied to vessel from
RBD silo through pipelines at a temperature of about 49ºC. Powdered sugar
of about 33kg per batch is supplied to vessel through Powdered Sugar
Services tank and thirdly SMP 950gm is provided manually to the creamer
vessel. Finamul is used as an emulsifier which is mixed with Ghee. In 800kg
of Ghee, 2.490kg Finamul is mixed. Particularly in each batch 0.065kg
Finamul is added with 20.900kg of Ghee. Finamul is directly supplied
through pipeline with ghee to the creamer vessel. CV Agitator is attached to
the vessel to agitate the ingredients properly.

3. LIQUID VESSEL:-

Liquid vessel receives SSA (Soda +Salt+ Ammonia), Sugar Syrup, PFM (Parle
Flavor Mix), and water. 2.5kg of SSA is provided manually to vessel. About 11kg of sugar syrup and 11kg of
water is supplied to the vessel through pipelines. Only 190ml of PFM is used in a single batch. Temperature
of sugar syrup should be about 42ºC and for water temperature should be 2.6ºC during summer time. Color
of sugar syrup is Golden Brown. BRIX for sugar syrup is about 75 – 80 and pH is about 2.9.
 LV Agitator is attached to vessel to agitate the ingredients properly. The amount of SSA should be in
such a way that 300gm soda + 1200gm ammonia + 650gm salt is to be taken per batch. Ammonia is used
for puffing of biscuits during baking and to maintain the stack height of biscuits. If the amount of ammonia is
more than the stack height will increase and vice versa.

Another Paste preparation machine is also fixed at mixing site to make RB paste of Reprocessed
Biscuit. This RB Paste is also mixed in dough with 7kg per batch. Sigma mixer is used in to prepare paste.

In Parle plant the total weight of single batch is about 204kg. It may vary from 202kg to 205kg per
batch.

STEPHEN MIXER

The Stephan TK Mixer is an ideal component to fully automatically feed the down-stream make-up
equipment for biscuits. After receiving the different ingredients from three vessels it works to mix them in
proper way. There are two types of motor attach to it to mix all materials properly. One is Baffle motor and
other is Mixer motor. Baffle motor rotates in two directional motion one is clockwise direction during
discharge of mixture to the hopper and another is in anticlockwise direction during mixing. Rotation round in
Stephen Mixer is about 600 to 700 revolutions. Quality improvement and automatic batching are the main
advantages of the Stephan Mixer. Biscuits and rolls will have bigger volumes, more uniform texture and a more
tender and delicate crumb. High volume output results from the short kneading time and fast ingredient charging 1000
kg/h to 6000 kg/h depending on the model. In a few seconds, all ingredients are homogeneously mixed. When all
material is mixed properly mixture is discharged in the hopper which is a part of rotary section. Brine solution is used
around the Stephen Mixer to make the temperature cool about -15ºC.

The operation can be divided into four phases:-- loading, mixing,

kneading and discharging. After loading the mixer wi th all ingredients, the mixing
starts.

The unique shape of the mixing/kneading tool, combined with the mixing baffle, produces a very
homogeneous mix. The combination of the mixing tool allows for the optimum hydration of the flour. Due to
this intensive hydration, a higher yield is possible in the range of 1.5-3% depending on the type of dough.
This complete development leads to a delicate crumb and an extremely machine able dough. Using a
special attachment, the Stephan Mixer can knead the dough’s under a vacuum, if it is desired to have a
super fine pore structure like American or English white pan bread

STEPHAN MIXER
Rotary:-
Rotary hopper has rotary blades to rotates and mix it finally as the
final dough is formed. Dough temperature is about 33.5ºC. Roller rolls the
dough and cutting knife help in cutting the dough in spreaded form so
that dough should pass from roller die equivalently and each cup of
die receives appropriate amount of dough to form biscuits. Rubber
roll provide a pressure to dough of 2.5kg for better shape of biscuits
in die. Rubber lined anvil roller is adjustable in height so that pressure can
be controlled at both sides in parallel or independently. The anvil roll is
being driven by friction of the cutting web, which is independently powered
by its own separate drive. For safety reasons the cutting roll is provided with
guard, removal of which stops the motor.
Roller Die drum has 12 cups in circle and 31cups in length of the die drum. Die give the shape and size to
biscuits and also imprint the name of product on biscuit i.e. Parle G on the top side of biscuits. After this biscuits are
passed on to rotary belt. Then these biscuits are conveyed up to oven and these biscuits are passed on the wire band
belt fin oven.
 Biscuits At Wirement After Rotary

OVEN:-
The oven body consists of steel steam tight tunnel with equally
divided zones of the radiators. Stainless steel expansion joints are provided
between these zones in order to eliminate the expansion of the oven section.
The inspection doors are provided for inspection of the baking goods during
the process. Length of oven is 324 feet from drum to drum.

The complete chamber is insulated with heat proof wall from outside
to conserve heat and increase efficiency. This insulated chamber reduces the
chance of heat loss into the surrounding atmosphere .The fully automatic
imported burner shall be fitted to the chamber and the temperature shall be
controlled by automatic temperature controller on the control panel. The
complete oven will be covered with 10" thick mineral wool insulation from
top, bottom and the sides. The bottom portion of the oven at the sides will be
covered with CRC sheets for the conveyor protection and to avoid heat loss.
In oven total numbers of burners are 333. There are three types of burners:

1. Balancing burners = 125 in number

2. Non Balancing burners = 190 in number
 19

3. Preheating burners = 18 in number

Preheating burners works as to heat the wire band which is going in the
reverse direction toward the rotary. Total length of oven is divided in three
zones i.e. first 30% length of oven is known as puffing zone, middle 40%
length of oven is known as baking zone and last 30% length is known as
coloring zone. Temperatures in the oven is in parabolic range during starting
and end three zones temperature will be less and in middle four zones, the
temperature will be high up to 320±20ºC.

Oven Temperature Range:-

At RPM – 32 :-

Zone Zone Zone Zone Zone Zone Zone Zone Zone Zone
1 2 3 4 5 6 7 8 9 10
Upper 220±20 240±20 260±20 280±20 290±20 300±20 275±20 245±20 240±2 220±20
0

Bottom 200±20 230±20 250±20 270±20 285±20 290±20 250±20 230±20 235±20 190±20
 20

There are damper plates at each zone of oven whose opening and
closing maintain the steam inside the oven. During first three zones damper
plates are 20% to 30% open, so as to maintain the steam in oven for better
puffing of biscuits. In zones no. 4, 5, 6 & 7 the damper plate is open about
40% to 60% at this level biscuits are baked and temperature of these is also
high. And last three zones i.e. 8, 9 & 10 the damper plates is almost totally
opened to released all steam from the oven. Last three zones are known as
coloring zone.

Zones no. 6, 7 & 8 is known as CCP zone (Critical Control Point).

Minimum temperature of CCP zone is 230ºC to 320ºC.These zones helps in
controlling the moisture of biscuits and also increase the shelf life of the
finished product. This CCP zone is most important zone among all other
zones because it maintains the shelf life of the biscuits. CCP should be
monitored time to time to ensure that this zone is receiving the desired
temperature range or not. When biscuits are fully baked at the 10 th zone they
are released on the cooling conveying belt for better cooling of hot baked
biscuit. Color of fully baked biscuit is Golden Brown.

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. The biscuit continues to run on it for 5 to 7 minutes so
that the biscuits become cool and all the moisture that biscuits contain gets evaporated. And because of the above
reason the factory has “S FLOW LAYOUT” in the factory. A metal detector is placed after cooling when
biscuits move towards packing so that to ensure that the biscuit is free from any metallic contamination. This
will help in reducing the chance of contamination in biscuits.

Packing:-
The conveyor continues to move to counting table where biscuits are
counted and seen that it is going on properly or not. The conveyor continues
till the biscuits reach the STALKING TABLE at which the biscuits are packed in very orderly
manner.
From cooling conveyor sum biscuits are diverted through AUTO FEEDING MACHINE to another
stalking machine where packing is done. In auto feeder machine has inline pusher having 6 shots and cross
pusher. Cross pusher maintain the counting of biscuits such as 16 biscuits in one packet.
 Particularly stack height of biscuits is also check at this level. The
stack height of 16 biscuits is 122mm.Weight of 16 biscuits at rotary is
104gm. Weight of 4 biscuits after coming out from oven is 22.4gm. Stack
height should be checked every one hour to maintain the profit of company,
because if stack height will increase then profit will reduce. Stack height is
monitored by regulating the amount of Ammonia & Water during mixing.

Auto Feeder machine has a control panel to control cross pusher.

From stalking table the biscuits are moved on conveyor to MULTI PACK
WRAPPING MACHINE were 16 biscuits are packed into a regular Parle
G wrapper so that the weight of 16 biscuits comes up to 120±2 grams.

Machine speed is about 132-135 PPM. Plant runs on 35 RPM. On

increasing 1 RPM then 3.5 PPM will increase. During sealing of packet the
temperature of UJ (Upper Jaw) is 138ºC and LJ (Lower Jaw) 139ºC. There
are two roller sealers i.e. RL1 & RL2 for bottom sealing. Temperature of
RL1 is 202ºC and RL2 is 205ºC. When 16 biscuits are packed in plastic
wrapper these packets are conveyed in forward direction.Then 24 packets of
Parle G biscuits are packed into a POLY BAG. And after packing it into
poly bag it is sent to SEALING MACHINE where it is sealed, then it is
sent to CORRUGATE BOX SECTION in which 6 poly bags are placed
manually and box is conveyed for final sealing.

TAPPING MACHINE:-
 Six such poly bags are placed in one such corrugated box and the box
is passed through the tapping machine where the boxes are tapped and
labeling of date, batch no. and other detail is also done at this tapping
machine, then these are sent through a long diversion conveyer belt. This
belt helps to transfer the box to the dispatch section directly. 36 boxes are
arranged on pallet in the dispatch section, from where they are transferred to
the various dealers all over the India and worldwide

Intended Use Of ‘parle G’ biscuits…

Where it is sold..?? Directly to the consumers of

India and abroad.

Who will consume.? People of all age group except

below one year infants.

Sensitive consumer Glutin Allergic,

Diebitic Person,
Infants below 01
year.

Some Important Details about…

 Raw Materials:-

Maida
Moisture 13% (12±1)
Sedimentation value 18-23ml
Glutein percentage 8%-10%
Alcoholic acidity W.B.- 0.62 & D.B.- 0.65
Total ash 1%
Acid insoluble ash 0.04%

RBD
PV (Peroxide value) 1.25meq/kg
Free Fatty acid 0.1 %( max.)
Iodine value 45-56
Moisture percentage 0.1%
Melting Point 35ºC to 37ºC

S.M.P.
Moisture percentage 4%
Total ash 8.2%
Protein 34%

MISSLANIOUS
Reasons for increasing Stack Height:-
There are various factors due to which the stack height of biscuits will
increase. Following are the reasons which increase stack height:

1) Dough Quality

 Quantity of Ghee is less.

 Quantity of sugar is less.

 Dough temperature is more.

 Increase in amount of Ammonia.

2) Molding

 More weight of biscuit.

 Pressure due to Roller is less.

3) Baking

 Damper position.

 Proofing zone has high temperature.

Reason for increase in length of Biscuit:-

1) Dough Quality

 Moisture content of dough is less.

 Amount of sugar is less.

  Amount of Ghee is less.

 Mixing time is more.

 Reprocess able dough is more.

2) Baking

 Distance between two biscuits is more on wire band.

3) Rotary

 Speed of Rubber Roll is more.

 Standing time at proofing zone is more.

Reasons for increase in width of Biscuits:-

1) Dough Quality

 Consistency of dough is not proper.

 Amount of Ghee is more.

 Amount of sugar is more.

 Particle size of sugar is small.

 Particle size of Maida is small.

2) Mixing

 Mixing time is less.

 Improper temperature of dough.

3) Baking
  Bottom temperature is less.

 Mostly damper plates are closed.

 Temperature of 1st zone is less.

4) Molding

 Weight of biscuits is more.

 Excessive pressure of Rubber Roll.

WASTAGES:-
If an industry produces some products on a large scale then there is
also a chance of wastage of raw material or any other material used in
production. There are various types of wastage in production of biscuits.
Wastages includes like wastage of ingredients used in production, dropping
wastage, wrapper, corrugated box and such other. During mixing the
wastage of raw material are as follows:

List of Raw Materials Wastage (in gm) per shift

Maida 240- 280

Sugar 200-250
 Paste 300
SMBS 25
ABC 1020

Same as during packing there is dropping wastage i.e. dropping of

biscuits or damaging of biscuits which is about 15kg to 30kg per machine
per shift. These biscuits are further reprocessed and known as RB Paste.
During packing of biscuits in packing area there is wastage of wrapper at
each packing machine is about 300gm – 450gm wrapper per shift. It may
vary from machine to machine. If there is any technical problem related in
packing machine then this value may varies. At last there is a chance of
wastage of corrugated box in which 6 poly bags are packed. Wastage of
corrugated box is about 20 boxes to 30 boxes per shift.

Specification of finished biscuits

ph 6.8-7.0
Moisture less than 2.0%
Ash 1.5 (max.)
Fat 13.0(min)
Acidity of extracted fat 1.0 (max)

Specification of biscuits shelf life study

S.N Date Moistur Fat Taste Smell
e
1 07-06-2010 1.81 12.89 OK OK

2 08-06-2010 1.85 12.75 OK OK

3 09-06-2010 1.90 12.98 OK OK

4 10-06-2010 1.83 12.97 OK OK

5 11-06-2010 1.85 12.85 OK OK

Factors affecting Processing of Biscuits

 The major factor governing the eating chacterstics of glucose biscuits

is the consistency of dough formed as a result of mixing. The nature
of viscoelastic properties of dough mainly governs the texture,
spread, color and bite of the resulting biscuits. This depends upon
nature of the flour,and its glutin forming chacterstics. More extensible
or less elastic dough is desired during biscuit manufacturing.

 Sometimes improper mixing of fat and water in the batch results in

excess glutin formation ,as te flour is more in contact of water. This
causes the dough to become less extewnsible or more elastic leading
to improper spread and texture of the biscuit. This can be overcome
 by ‘creaming ’ of fat using emulsifier (eg. Lecithin or finamul) and
then mixing with water so that it vforms a good emulsion of both.
This causes the dispersion of fat evenly thoughout the dough and
limits the formation of glutin.

 Sugers, depending upon the leveland type effect therheological

chariostics of the dough . increasing the suger content reduces the
extrusion time, dough consistency, biaxial extensional viscosity and
increases the spread. Development of glutin is also reduced and there
is an improvement in the texture of biscuits.

 Incorporation of additional reducing suger, particularly liquid

glucoseee and syrup limits glutin formation and produces changes the
adhesiveness and stickiness of the dough.

 The mixing time as well as the standing time of the dough also affects
its characterics.if the dough after mixing is allowed to stand for a
longer period, glutin formation enhances and the dough become
harder.

 The content of leavening agent in the dough as well as condition of

temperature and pressure inside the oven influence the baking
characterstics to a great extent . biscuits baked under reduced paper
than the normal have better textural profiles .

 The control of moisture in the biscuit is critical to insure its greater

shelf life and microbiological safety as spoilage accelerates in
presence pf high moisture content .as soon as the biscuit cools,it must
be paked in minimum possible time so that it does not absorb
moisture from the surrounding atmosphere .

 Emulsification improves the ablity of the protein film to entrap air in

the batter duringcreaming or mixing .thus the biscuit opn outmore
 during the biscuit,thus improving the palatability .the biscuit made
byusing emulsifier have more crispness.

 Colour of the biscuits is due to-

 Mallard reaction
 Ceremelization of suger

 Time requires to bake the biscuits in oven is generally 3-4 min.Baking

time depend on rpm of die and rotary.
Higher the RPM, lower will be the baking time & vice versa.

 Generally one dough batch servives upto 15 min and nearly 20

batches are served per hour, depends on RPM of rotary & staker.

 CCP for physical hazards [Metal] is checked at rotary as well as

cooling conveyor for which metal detector is placed. CCP for metal
detector is:
 For ferrous = 1.5 mm
 For non-ferous = 2.0 mm
 For S.S. = 2.5 mm

Conclusion

The Pantnagar plant location of the company involved with he

manufacturing the glucose biscuit Parle-G . Generaly biscuits are small
chemically leavened baked product made principally form flour suger and
fat .their glucose biscuit contain relatively more fat and sugar content and
fall under the category of sweet biscuit .The sugar used is mainly in the form
of glucose and hence it is called glucose biscuit .They form a health diet and
a good source of energy as well as re economically cheaper than another
vareity of biscuit around 65% of total biscuit manufactured in india are
glucose biscuits.
Some time defects lie cracking choking, excessive spreading perishin
can detected in the biscuits but these problems hence relevant remedies.

The elasticity of dough mainly governs the texture, color and bite of
resulting biscuits.The in turn depend on the nature of the flour and its glutin
forming characteristics. A less elestic and more extensible dough is desirable
during biscuit making. Suger depending on the level and type effect the
rheological characterstics of the dough . development of glutin is also
redused and there is improvement in the texture of biscuits. The mixing
time as well as standing time of the dough also affects . Its characterstics
gluten formation enhance and dough become harder condition of temprature
and pressure inside the oven influence the baking charecterstic to a great
extent the control of moisture in the biscuit is critical to insure it greater
shell life and microbiological safety . As soon as the biscuit is cooked it
must be packed in minimum possible time so that it does not absorb
moisture from the sorrounding atmosphere.

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