Industrial Training

At

HALDIRAM SNACKS PVT. LTD.

B-1, Noida Sector-63,
Uttar Pradesh-201307

An Industrial Training Report Submitted

In Partial Fulfillment of the Requirements
For the Degree of

BACHELOR OF TECHNOLOGY
By
KRITIKA SINGH
1700482017

B.Tech. Food Technology 7th Semester

RAJA BALWANT SINGH ENGINEERING TECHNICAL CAMPUS
BICHPURI, AGRA

to the

FACULTY OF FOOD TECHNOLOGY

DR. A.P.J. ABDUL KALAM TECHNICAL UNIVERSITY

U.P., LUCKNOW

(Formerly Uttar Pradesh Technical University, Lucknow)

January,2021
 ACKNOWLEDGEMENT
First and foremost, I convey my sincere gratitude to our Academic Head Prof. (Dr.) Apoorva
B. Lal, Head of Department of Food Engineering & Technology, R.B.S Engineering Technical
Campus, Bichpuri, Agra. Without his continuous motivation and constructive criticism this
training would have not been this successful. Along with him I am grateful to our generous
faculty members for inculcating and infusing in students the confidence to take up challenges,
ability to think big and to be a leader.

I want to express my deepest thanks to Dr. A. K. Tyagi, Executive Director, for allowing me
to carry out my training program in this company.

It is a privilege and pleasure for me to work at Haldiram’s Snacks Pvt. Ltd. under the
profound guidance of Ms.Shailly Singh (Manager- QA). I am grateful to her for her keen
interest, constant encouragement and constructive criticism. I express my profound sense of
indebtedness to Mr. Ajay Kr. Shrivastwa (Institutional Sales Manager), who helped me get
this internship opportunity in the first place.

I would like to thank my seniors who helped me greatly to complete this report. Finally, I am
deeply indebted to my family and friends who always give us constant support and
encouragement.

To conclude, we bow our head in reverence and submission to Almighty who bestowed the
strength to accomplish this task.

2
 TABLE OF CONTENTS

1.Introduction……………………………………………….Page.4-5
2.Mission…………………………………………………….Page.6
3.Certificates and Accolades……………………………….Page.7
4.Product Range………………………………………….…Page8
5.Quality Control Department…………………………....Page.9-14
(i)Caliberation of lab equipments…………..……… Page10
(ii)Equipments in quality control lab…………………Page.11-14
6.Tests performed in laboratory……………………….Page15-34
7.Cleaning and Sanitisation……………………………Page.34-40

3
 INTRODUCTION
HALDIRAM” – a name associated with discerning consumers for sweets and namkeens for

past seven decades in India and abroad. It made its modest start in the beginning of 1937 in
Bikaner, a city of Rajasthan, India and was founded by Shivkishan Aggarwal. The brand
name HALDIRAM BHUJIYAWALA was introduced during pre-partition era – 1941,
subsequently the reach was extended to eastern part of India i.e. Kolkata in 1958, further
consolidated to western India also at Nagpur in 1968 and from there it never looked back and
ventured first major step in this direction by opening a showroom in Chandni Chowk in 1982,
the main hub of commerce in Delhi. The prime focus was to serve sweets and namkeens
amongst consumers and the trade it directly.

In 1970, a large manufacturing unit was set up in Nagpur in the state of Maharashtra (India).
In 1982, a retail outlet was set up in New Delhi. The outlet became very popular not only
among the Delhities but also among tourists visiting Delhi.Haldirams was able to achieve
significant growth during the 1980s and 1990s. In 1992, a manufacturing unit with a retail
outlet attached to it was set up in the outskirts of Delhi. A year later, Haldirams syrups and
crushes were successfully launched in the Indian market. In 1995, a restaurant was opened in
New Delhi. In 1997, realizing the potential of namkeens, the company started a
manufacturing unit in Delhi exclusively for making namkeens. The company offered a wide
variety of traditional Indian sweets and snacks at competitive prices that appealed to people
belonging to different age groups. It was the first company in India to brand namkeens‘.The
group also pioneered new ways of packaging namkeens. Its packaging techniques increased
the shelf life of namkeens from less than a week to more than six months. It was also one of
the first companies in India to open a restaurant in New Delhi offering traditional Indian
snack food items such as "panipuri," "chatpapri," and so on, which catered to the needs of
hygiene conscious non-resident Indians and other foreign customers. In the mid-1990s,
Haldirams added bakery items, dairy products, sharbats and ice creams to its portfolio. At the
beginning of the 21st century, Haldirams products reached millions of consumers not only in
India, but also in several other countries, including the US, Canada, UK, UAE, Australia,
New Zealand, Sri Lanka, Nepal, Japan and Thailand.

To add potato products to its existing product portfolio, machinery was imported from the
US. Haldirams maintained high quality standards at every stage of the production process.
All its food items were prepared and packaged in a very hygienic environment. Encouraged
by tremendous response of consumers, HALDIRAM‘decided to go for an up-gradation on
technology, packaging, production etc. with the installation of best machinery and hiring best
staff. Through hard work, complete dedication, uncompromising quality, -
HALDIRAM‘became a part of each family.

4
 Haldiram‟s story presents the perfect case of coming of age of a small-time business and
adapting to the changing tides of time, having redefined its business model over and over
again to keep up with the changing market dynamics and consumer behavior

At the beginning of the 21st century Haldiram’s products reached millions of consumers not
only in India but also in several other countries including the U.S, Canada, U.K, U.A.E,
Australia, New Zealand, Sri lanka, Nepal and Thailand.

Haldiram’s has many ‘Firsts’ to its credits. It is the first company in India to brand
‘Namkeens’ a popular Indian snack which is really easy to make without the use of large
machines. The Group pioneered new ways of packaging namkeens. Its packaging techniques
increased the shelf life of Namkeens from less than a week to more than six months. It is one
of the first companies in India to open a restaurant in New Delhi offering traditional Indian
snack food items such as “Panipuri” & “Chatpapri” which catered to the needs of hygienic
conscious of Nonresidents Indians and foreign customers.

Analysts felt that the growing popularity of Haldirams products could be attributed to its
constant focus on all the elements of the marketing mix. An article posted on the APEDAs
website - apeda.com quoted some of the company’s strengths, "To sustain in the competitive
market, Haldirams has endeavored stress on its product quality, packaging, shelf life,
competitive price with a special emphasis on consumers satisfaction and its lingering taste is
amongst the best available in the world."

5
 Mission
Review, Recreate and Rediscover the trend of Healthy Eating and Innovate and Invent fresh
new methods to nourish and Delight everyone we serve.
Vision
Be the Trend Setter in the field of Healthy and Tasty Eating to Achieve a Sustainable Growth
this will bring about an overall upliftment of the Organization, its People and the Society.
Goal
To provide our customers Perfect Taste and Quality in the Best of Packaging.

Haldiram's is a member of the following food associations from India and abroad:
• APEDA (Agriculture and Processed food Products Exports Development Association) India
• ITPO India Trade Promotion Organization (Application submitted)
• Snack Food Association|SFA (Snack Food Association)
• ESA (European Snacks Association)

Haldiram is on the way of its vision as today it is an ISO 22,000 & HACCP certified
company

6
 CERTIFICATIONS AND ACCOLADES

• Haldiram's has been the proud recipient of many awards such as the International Food
award from TROFEO International Alimentation of Barcelona, Spain (1999).
• Shri Shivkishanji Agrawal, Chairman of Haldiram's Group has also received a regional
award, titled "VIDARBHA GAURAV PURASKAR"
• The Group has also to its credit 'KASHALKAR MEMORIAL AWARD' presented
by 'All India Food Preservers Association' (Regd.) in 1996 at its Golden Jubilee
Celebration for manufacturing best quality food products.
• 'BRAND EQUITY AWARD 1998' was awarded by Progress Harmony Development
Chamber of Commerce & Industry through Shri Yashwant Sinha, former Union
Finance Minister recognizing the successful creation of Indian Brand 'HALDIRAM'S'
• Haldiram’s has also been awarded with APEDA EXPORT AWARD for its highest
quality products.
• Haldiram is pleased to certify that all their products are BRC ‘A’ Certified and are
regularly audited under the guidelines provided by BRC by our professional quality
team. They invest in the newer and better process in order to make our products of
superior quality.

They have some systems and procedures which support in maintaining of degree of excellence

• Regular gathering and monitoring of customer feedback.

• Performance monitoring of supplier against set criteria.
• Training and development of employees.
• Regular audit of internal process.
• Management reviews of audit result, customer feedback and complaints

7
 Product range
Haldiram has successfully completed the journey of being a small entrepreneur to the India’s
largest selling brand name in Sweets and Namkeens (savory). The entity is known for its
variety of mouthwatering food products such as Sweets, Namkeens, Pickles, Syrups, and
Biscuits in the world. The prime focus of the company is to serve sweets and savories directly
to customer. The impeccable range of products at Haldirams includes: Sweets: Jamphal,
Bengali Rasgulla, Pateesa, Raj Bhog, Nargisi Rolls and many more. Syrups/Sharbats: Khus,
Thandai, Rose Flavor, Orange Flavor, Badam and Pineapple Flavor Pickles: Green Chili,
Lime, Mango and Mixed Pickle Namkeen: Aloo Bhujia, Hara Chiwda, Kaju Mixture,
Navrattan, Moong Dal, Bhujia, Cornflakes Mixture, Kashmiri Mixture, Nut Cracker, Khatta
Meetha. Potato chips and various products in chips range. Apart from this Haldiram‘s
restaurants offer a large variety of food ranging from Indian snacks, North Indian food, South
Indian food, Continental and Chinese, Italian food and also many drinks to freshen up their
customers.
However, namkeens remained the main focus area for the group contributing close to 60% of
its total revenues. By specializing in the manufacturing of namkeens, the company seemed to
have created a niche market. While the Nagpur unit manufactured 51 different varieties of
namkeens, the Kolkata unit manufactured 37 and the Delhi unit 25.
The raw materials used to prepare namkeens were of best quality and were sourced from all
over India.Haldirams sought to customize its products to suit the tastes and preferences of
customers from different parts of India. It launched products, which catered to the tastes of
people belonging to specific regions. For example, it launched Murukkus, a South Indian
snack, and Chennai Mixture for south Indian customers. Similarly, Haldirams launched
Bhelpuri, keeping in mind customers residing in western India
.
. These measures helped Haldirams compete effectively in a market that was flooded with a
variety of snack items in different shapes, sizes and flavours.Pricing Haldirams offered its
products at competitive prices in order to penetrate the huge unorganized market of namkeens
and sweets. The company’s pricing strategy took into consideration the price conscious
nature of consumers in India. Haldirams launched namkeens in small packets of 30 grams,
priced as low asRs.5. The company also launched namkeens in five different packs with
prices varying according to their weights. The prices also varied on the basis of the type of
namkeens and the raw materials used to manufacture it. The cost of metallized packing also
had an impact on the price, especially in the case of snack foods. The company revised the
prices of its products upwards only when there was a steep increase in the raw material costs
or additional taxes were imposed. The company also launched namkeens in five different
packs with prices varying according to their weights. The prices also varied on the basis of
the type of namkeens and the raw materials used to manufacture it.

Source:http//haldirams.com

8
 QUALITY CONTROL DEPARTMENT

Quality control, or QC for short, is a process by which entities review the quality of all
factors involved in production. ISO 9000 defines quality control as "A part of quality
management focused on fulfilling quality requirements"

Quality control emphasizes testing of products to uncover defects and reporting to

management who make the decision to allow or deny product release, and quality assurance
attempts to improve and stabilize production (and associated processes) to avoid, or at least
minimize, issues which led to the defect(s) in the first place.

The responsibilities for QC are as follows:

1. Approve or reject all procedures, specifications, methods, and results.

2. Approve or reject all raw materials, packaging materials, labelling and finished products.

3. Review all production records for accuracy and completeness before approving for
distribution.

4. Establish procedures for revising procedures, formulas, etc.

5. Approve changes to procedures, formulas, etc.

6. Ensure that the latest revision is being used at all times.

7. Perform all the required tests to ensure identity, purity, potency and composition, and to
ensure that products are not contaminated or adulterated

Haldiram’s pay the utmost attention for selecting the finest raw material; this is achieved
through proper quality management systems with the help of the suppliers through internal
review procedure.

They have some systems and procedures which support in maintaining of degree of excellence

• Regular gathering and monitoring of customer feedback.

• Performance monitoring of supplier against set criteria.
• Training and development of employees.
• Regular audit of internal process.
• Management reviews of audit result, customer feedback and complaints

9
 CALIBRATION OF LAB EQUIPMENTS
1. WEIGHING BALANCE -
WEIGHING SCALE is a measuring instrument for determining the weight or mass of
an object. weighing scales are used in many industrial and commercial applications,
and products from feathers to loaded tractor-trailers are sold by
weight. An analytical balance is a class of balance designed to
measure small mass in the sub-milligram range. The measuring
pan of an analytical balance (0.1 mg or better) is inside a
transparent enclosure with doors so that dust does not collect
and so any air currents in the room do not affect the balance's
operation.

2. CALIBRATION OF REFRACTOMETER
Refractometers are increasingly popular quality-assurance tools in the food, beverage,
ingredients, and flavors industries. They are used to determine the integrity and purity
of raw materials that make up finished goods. They are also used to
determine the concentration of dissolved solids in a solution.
Refractometers ensure good, consistent quality of product and, more
importantly, they help to control production costs, thus saving
money and maximizing profits.

3. CALIBRATION OF PH METER ----

A pH meter is an electronic device used for measuring the pH (acidity or alkalinity) of
a liquid (though special probes are sometimes used to measure
the pH of semi-solid substances). A typical pH meter consists of
a special measuring probe (a glass electrode) connected to an
electronic meter that measures and displays the pH reading.

4. CALIBRATION OF TDS METER --

A TDS Meter indicates the Total Dissolved Solids (TDS) of a solution, i.e. the
concentration of dissolved solids in it. Since dissolved ionized solids such
as salts and minerals increase the conductivity of a solution, a TDS meter
measures the conductivity of the solution and estimates the TDS from that.
dissolved organic solids such as sugar and microscopic solid particles such as
colloids, do not significantly affect the conductivity of a solution so a TDS meter
does not include them in its reading.A TDS meter typically displays the TDS
in parts per million (ppm). For example, a TDS reading of 1 ppm would indicate there
is 1 milligram of dissolved solids in each kilogram of water.

10
 EQUIPMENTS USED IN Quality Control Laboratory

Autoclave

An autoclave is a pressure chamber used to carry out industrial processes at temperature and
pressure different from ambient air pressure. Autoclaves are used in medical applications to
perform sterilization and in the chemical industry to cure coatings and vulcanize rubber and for
hydrothermal synthesis. Industrial autoclaves are used in industrial applications, especially
regarding composites. Many autoclaves are used to sterilize equipment and supplies by
subjecting them to pressurized saturated steam at 121 °C for around 15-20 minutes at 15 psi
pressure depending on the size of the load and the contents. The autoclave was invented by
Charles Chamberland in 1884. The name comes from Greek auto meaning self and Latin clavis
meaning key, thus a self-locking device.

B.O.D Incubator

BOD incubator is the most versatile and reliable low temperature incubator which is designed
to maintain at 20°C, necessary for Biological Oxygen Demand/Biochemical Oxygen
Demand (BOD) determination. BOD incubators provide controlled temperature conditions for
accelerated tests and exposures. The biological oxygen demand (BOD) is an empirical test in
which standardized laboratory procedures are used to determine the relative oxygen
requirements of microbes in wastewaters, effluents, and polluted waters and in simple words,
it is a chemical process that determines how fast biological organisms use up oxygen in a body
or it measures the oxygen required for the biochemical degradation of organic material and the
oxygen used to oxidize inorganic materials, such as sulphides and ferrous iron.

Centrifuge

A centrifuge is a piece of equipment that puts an object in rotation around a fixed axis applying
a force perpendicular to the axis of spin (outward) that can be very strong. The centrifuge works
using the sedimentation principle, where the centrifugal acceleration causes denser substances
and particles to move outward in the radial direction. At the same time, objects that are less
dense are displaced and move to the centre. In a laboratory centrifuge that uses sample tubes,

11
the radial acceleration causes denser particles to settle to the bottom of the tube, while low-
density substances rise to the top.

Hot air oven

Hot air oven is electrical device which uses dry heat. It is originally developed by Pasteur.
Generally, they use a thermostat to control the temperature. Their double walled insulation
keeps the heat in and conserves energy, the inner layer being a poor conductor and outer layer
being metallic. There is also an air filled space in between to aid insulation. An air circulating
fan helps in uniform distribution of the heat. These are fitted with the adjustable wire mesh
plated trays or aluminum trays and may have an on/off switch, as well as indicators and controls
for temperature and holding time. The capacities of these ovens vary. Temperature sensitive
tapes or biological indicators using bacterial spores can be used as controls, to test for the
efficacy of the device during use.

Laminar air flow

A laminar flow cabinet or tissue culture hood is a carefully enclosed bench designed to
prevent contamination. Air is drawn through a HEPA filter and blown in a very smooth, laminar
flow towards the user. Due to the direction of air flow, the sample is protected from the user
but the user is not protected from the sample. The cabinet is usually made of stainless steel
with no gaps or joints where spores might collect. Such hoods exist in both horizontal and
vertical configurations, and there are many different types of cabinets with a variety of airflow
patterns and acceptable uses. Laminar flow cabinets may have a UV-C germicidal lamp to
sterilize the interior and contents before usage to prevent contamination of experiment.
Germicidal lamps are usually kept on for 15 minutes to sterilize the interior and no contact is
to be made with a laminar flow hood during this time. During this time, scientists normally
prepare other materials to maximize efficiency. (It is important to switch this light off during
use, to limit exposure to skin and eyes as stray ultraviolet light emissions can cause cancer and
cataracts.)

MilkoScreen

MilkoScreen analyses the product using Fourier Transform-Infrared technology, assessing

milk constituents, using absorption at different wavelengths in the infrared spectrum to detect

12
the presence of specific parameters in milk like Fat, SNF and Protein. Accuracy and
repeatability of results are comparable with the chemical methods, but with MilkoScreen it
takes far less time than conventional chemical methods. Results from MilkoScreen are accurate
and direct.

Muffle furnace

Muffle furnace refers to a type of jacketed enclosure that is used to heat a material to
significantly high temperatures while keeping it contained and fully isolated from external
contaminants, chemicals or substances. Muffle furnaces are usually lined with stainless steel,
making them largely corrosion resistant. Muffle furnaces were designed to combat the
associated outcomes of heating via combustion. Such outcomes include a variety of unwanted
by-products such as ash, soot and gas fumes. The generation of these by-products often present
as impurities to the material being heated. Muffle furnaces are capable of reaching and holding
temperatures as high as 1800°C. With the invention of high temperature electric heating
elements in the early 50’s however, most furnace manufacturers quickly converted their muffle
furnaces to electric where the by-products of heating are negligible for most processes.

Soxhlet Apparatus

A Soxhlet extractor is a piece of laboratory apparatus invented in 1879 by Franz von Soxhlet.
It was originally designed for the extraction of a lipid from a solid material. Typically, Soxhlet
extraction is used when the desired compound has a limited solubility in a solvent, and the
impurity is insoluble in that solvent. It allows for unmonitored and unmanaged operation while
efficiently recycling a small amount of solvent to dissolve a larger amount of material. A
Soxhlet extractor has three main sections: a percolator (boiler and reflux) which circulates the
solvent, a thimble (usually made of thick filter paper) which retains the solid to be extracted,
and a siphon mechanism, which periodically empties the thimble.

Water activity meter

Water activity is the ratio of the vapor pressure of water in a material or substance to the vapor
pressure of pure water. Water activity measurements are determined from a calculation of
relative humidity. Relative humidity is the percentage of water in the air (vapor pressure)
compared with the total amount of water that the air could hold (saturation vapor pressure) at

13
a given temperature. A water activity test works by placing a sample in a sealed measuring
container. When the vapor pressure of the water in the substance and the water in the air reaches
equilibrium, the relative humidity of the air surrounding the sample is equal to the water activity
of the sample.

Water bath

A water bath is laboratory equipment made from a container filled with heated water. It is
used to incubate samples in water at a constant temperature over a long period of time. All
water baths have a digital or an analogue interface to allow users to set a desired temperature.
Utilisations include warming of reagents, melting of substrates or incubation of cell cultures.
It is also used to enable certain chemical reactions to occur at high temperature. Water bath is
a preferred heat source for heating flammable chemicals instead of an open flame to prevent
ignition. For all water baths, it can be used up to 99.9°C. When temperature is above 100°C,
alternative methods such as oil bath, silicone bath or sand bath may be used.

Butyrometer

Butyrometer is a measuring instrument used to measure fat content in milk or milk products
in general. The method used in the determination is Gerber's method as invented by Swiss
chemist Niklaus Gerber. Separation of fat of the milk in a butyrometer by centrifuging after
dissolving the protein with sulphuric acid, the separation being aided by the addition of a small
quantity of amyl alcohol. The butyrometer is graduated to give a direct reading of fat content.

Refractometer

A refractometer is a laboratory device for the measurement of an index of refraction. The

index of refraction is calculated from Snell's law. Standard refractometer measure the extent of
light refraction (as part of a refractive index) of transparent substances in either a liquid or solid
state; this is then used in order to identify a liquid sample, analyse the sample's purity and
determine the amount or concentration of dissolved substances within the sample. As light
passes through the liquid from the air it will slow down and create a ‘bending’ illusion, the
severity of the ‘bend’ will depend on the amount of substance dissolved in the liquid. For
example, amount of sugar in a glass of water.

14
 TESTS PERFORMED IN LABORATORY

1. TESTS FOR MILK

(a) Butyro Refractometer Test

Aim: To test adulteration of the given milk sample with vegetable oils.

Materials Required: Butyro refractometer, lab centrifuge machine, heating plate, dish,
spatula, tissue paper, and cotton and milk sample.

Chemicals Required: Ethanol

Procedure:

1. The given milk sample is placed in the centrifuge and the fat separated is collected in a
dish.
2. Dish is heated to melt the fat by keeping it on the heating plate.
3. The oil separated is placed in the Butyro refractometer and the reading is noted down.
4. After taking the reading the butyrometer must be cleaned properly and gently with
ethanol and cotton to remove any residual oil.

Note: - Time – 5 minutes

RPM - 2500-2600

Observation: Readings for pure cow fat ranged from 41.10 to 42.20 with an
average of 41.57, whereas that for pure buffalo fat ranged from 40.20 to 41.20
with an average of 40.72.

(b)Fat Estimation

Aim: To estimate fat using gerber method.

Materials Required: Butyrometer, centrifuge, pipette.

15
Reagents Required: Sulphuric acid, amyl alcohol.

Procedure:

1. Take 10ml of dilute sulphuric acid in a butyrometer.

2. Add 10.75ml of the given milk sample and 1ml amyl alcohol.
3. Mix it slowly and gently.
4. Then set the butyrometer in the centrifuge for 5min at 3000rpm.
5. After 5min fat appeared in butyrometer scale is noted.

Observation:

Name of the Dairy Fat Present

Balaji 3.3
Indraraj 5.9

Hence, the milk received from Balaji dairy is cow’s milk and the milk received from Indraraj
dairy is buffalo’s milk.

(c.)Ammonia Test

Aim: To test the presence of ammonia in the given milk sample.

Materials Required: 2ml pipette, test tube and milk sample.

Reagents Required: Nessler’s reagent.

Theory: Ammonium sulphate is added to milk because it increases lactometer reading by

maintaining the density of milk. It also increases the protein content of milk. Hence, used as
adulterant in milk.

Procedure:

1. Take 2ml of the given milk sample in a test tube using a pipette.
2. Add 2ml of Nessler’s reagent into the test tube using pipette.
3. Shake the solution thoroughly.

16
 4. Observe for a few seconds for any change of colour.

Observation:

If the contents turn yellowish-brownish in colour, this indicates presence of ammonia in the
given milk sample, but if there is no colour change observed, this indicates absence of
ammonia.

(D)Detergent test

Aim: To test the presence of detergent in the given milk sample.

Materials required: Pipette, test tubes and the milk sample.

Reagents Required: Methylene blue reagent*, chloroform.

Theory: Detergents are added to maintain acidity and prevent curdling and thus increase the
shelf life of milk. These could be added in the form of caustic soda, sodium bicarbonate or
sodium carbonate.

Procedure:

1. Take 10ml of the given milk sample in a test tube using a pipette,
2. Add 15 ml chloroform in it.
3. Then add 25 ml methylene blue reagent to it.
4. Keep still for 5-10 minutes and then observe.

Observations: Test is –ve, i.e., there is no presence of detergent. If light blue coloured layer
appears below the dark coloured layer. But if test is +ve, i.e., detergent is present if light blue
coloured layer appears above the dark coloured layer.

*Methylene blue reagent is prepared by adding 1 methylene capsule to 800ml distilled water
and then heating it.

17
 (e) Milkoscreen Test

Aim: To find out the Fat, SNF and Protein content of the given milk sample.

Materials Required: Tissue paper, beaker, heating plate, thermometer and the given milk
sample.

Chemicals Required: Distilled water, Cleaning solution.

Procedure:

1. Firstly, dip the probe of milkoscreen in cleaning solution and then cleaning is started.
2. Then the probe is dipped in distilled water for zero calibration.
3. Heat the given milk sample on heating plate till it is 400C.
4. Then the probe is dipped in the warm milk sample and fat, SNF and protein content of
the dipped milk sample is calculated digitally.

Observation:

Samples Fat SNF Protein

Sample 1 4.1 8.3 3.8
Sample 2 5.8 8.5 3.7
Sample 3 6.6 8.7 3.8
Sample 4 6.4 8.3 3.5

18
 2.TESTS FOR WATER

a.Total dissolved solids(TDS)

Aim: To determine total dissolved solids in water.

Material required: TDS meter, water sample and beaker.

Theory: A TDS is a measure of the combined total of organic and inorganic substances
contained in a liquid. This includes anything present in water other than the pure water
molecules. These solids are primarily minerals, salts and organic matter that can be a general
indicator of water quality. High TDS generally indicated hard water, which can cause scale
build up in pipes and appliances, which reduces performance and adds system maintenance
costs.

Procedure:

1. Take about 50 ml of the water sample in a beaker.

2. Switch on the TDS meter and dip it in water sample.
3. Note down the readings of the TDS meter when it gets stable.

Observation:

Date TDS

10/08/20 350

17/08/20 410

25/08/20 390

29/08/20 380

Result: The given water samples having appropriate amount of TDS and is fit for using and
for manufacturing of products. The standard which use in factory is less than 400.

19
 b.Hardness of water

Aim: To determine the hardness of water.

Required Apparatus: Burette, Pipette, Conical flask, beaker, and glass funnel.

Reagents required: EDTA solution (0.02N), hardness indicator tablet, ammonia buffer
solution.

Theory: The simple definition of water hardness is the amount of dissolved calcium and
magnesium in the water. Hard water is high dissolved minerals both calcium and magnesium.
EDTA (ethylene diamine tetra acetic acid) forms colourless stable complex with ca2+ and mg2+
ions present in water at ph=9-10.

Hardness Condition

Less than 50 Soft

50-100 Slightly hard

100-200 Hard

Above 200 Very hard

Procedure:

1. Take exactly 100 ml of water sample in a beaker.

2. Take a hardness indicator tablet and crush it.
3. Now add the crushed tablet to water sample and stir it.
4. Add 1ml of ammonia buffer solution to increase the pH. This help to dissolve the tablets
completely, this turns the sample to violet color.
5. Titrate the sample with EDTA until the color of water becomes blue. Note the readings
of the burette.

Calculation:

Total hardness= titer value*100(ppm)

Observation

20
 Initial value Final value Titer value Total hardness

0 0.4 0.4 40

1 1.6 0.6 60

2 2.6 0.6 60

3 3.5 0.5 50

5 5.6 0.6 60

Result: The total hardness of water sample is within range so the water is soft and slightly
hard and good for production use.

Precautions:

1. Readings should be noted carefully and accurately.

2. The hardness indicator tablet should not be touched with bare hands.

c. pH of water

Aim: To check the pH of water sample.

Material required: pH strips, water sample.

Theory: There are millions of chemicals in the world, some are acidic, some are basis, and
some are neutral. Acids are substances that produce free hydrogen ions (H+) when dissolved in
water. Bases are the substances that produce hydroxyl ions (OH- ions) when dissolved in water.

pH of a solution: The acidic or basic properties of a substance are measured in terms of pH. It
is the measurement of the hydrogen ion concentration. pH is defined as negative logarithm
(base 10) of hydrogen ion concentration.

pH= - log[H+] or pH = log 1/[H+]

Substances with pH lower than 7 are acidic, those with pH equal to 7 are neutral and those with
pH greater than 7 are basic in nature.

21
Procedure:

1. Take ample amount of sample water in a beaker.

2. Dip the pH strip in the water sample.
3. Note the change in color of the pH strip and match with pH scale given on the pH strip.

Observation:

Date pH

10/08/20 6.0

17/08/20 6.0

25/08/20 6.0

29/08/20 6.0

Result: The water sample having pH slightly acidic and suitable to be used in production of
products.

22
 3.MICROBIOLOGICAL TESTS

MEDIA PREPARATION:

• Take 4 conical flasks and label them.

• Add 2.350g of Violet Red Bile Agar in 100ml distilled water in the first flask.
• Add 4.153g Plate Count Agar in 100ml distilled water in the second flask.
• Add 3.596g of EMB Agar in 100ml distilled water in the third flask.
• Add 4.000g Chloramphenicol Yeast Glucose Agar in 100ml distilled water in the fourth
flask.
• Put cotton on the mouth of the entire four flasks and cover them with foil paper.
• Put all the flasks in the autoclave except the one with Violet Red Bile Agar, as Violet
Red Bile Agar is non-autoclavable.

PREPARATION OF PEPTONE WATER:

• Add 0.34g of Potassium Dihydrogen Orthophosphate to 10ml distilled water. Mark this
solution as A.
• Add 1.25ml of solution A to 1000ml distilled water to make peptone water.
• Now transfer 9ml of this solution to test tube and 99ml to the beakers.

PROCEDURE:

1. Switch on the UV light 15 minutes before starting the lab work.

2. Keep all the required materials in the lab before starting the experiment.
3. Sterilize the laminar flow hood area by ethanol using cotton swab.
4. Sterilize your hands with ethanol.
5. Label the test tubes and the beaker, with respect to different samples.
6. Label the plates, mentioning date and media.
7. Make one control plate for each medium.
8. In the beaker with 99ml of peptone water, add 10-11g of sample.
9. Add 1ml of solution using micro pipette from the beaker to test tube with peptone water
and label it according to the sample. Do this for each sample.

23
 10. Now take 1ml of the solution from test tube using pipette and pour it into 4 plates for
four different media.
11. After adding the sample to the plate pours the media into the plates and label
accordingly.
12. Now allow the media to solidify for 1hr.
13. After solidification of media incubate the plates into the incubator for colonies to
develop.
Note: - Plate count agar: total plate count [incubate for 24hrs at 360C].
Violet red bile agar: coliform [incubate for 48hrs at 360C].
Chloramphenicol yeast glucose agar: yeast/mould [incubate for 5 days at 240C].
EMB: E.coli [incubate for 48hrs at 360C].

RESULT: Less number of colonies were developed which were found to be safe for extended
shelf life of the product.

24
 4. TESTS FOR OIL

(a) Free Fatty Acid Test

Aim: To test the presence of free fatty acid in the given oil sample.

Materials Required: Spatula, weighing balance, conical flask, heating plate, titration
apparatus and oil sample.

Chemicals Required: Ethanol, phenolphthalein indicator, N/20 and N/10 NaOH solution.

Theory: Free fatty acids are produced because of lipolysis (hydrolysis of ester bonds in the
lipids which occur by enzymatic action; lipase). Formation of fee fatty acids cause the
development of dark colour, decrease in iodine value an decrease in tendency of oil to foam.
FFA is produced by the hydrolysis of oils and fats. The level of FFA depends on time,
temperature, and moisture content because the oils and fats are exposed to various
environments such as storage, processing, heating or frying, since FFA is less stable than
neutral oil, they are more prone to oxidation and to turning rancid. Thus FFA is a key feature
linked with the quality and commercial value of oils and fats.

Procedure:

1. Take 50ml of ethanol in a conical flask.

2. Add few drops of phenolphthalein indicator to it and titrate it against N/20 NaOH
solution so as to neutralize it (as it may contain some acids).
3. A pink colour is obtained as the end point.
4. Now weigh 10-11g of the given oil sample in the same conical flask and heat it on a
heating plate so that ethanol and oil is properly mixed together.
5. Again titrate it against N/10 NaOH solution.

End point of titration: A permanent cloudy pink colour is obtained.

25
Observation:

Samples Weight of oil N/10 NaOH

Initial Final
Sample 1 15.1 5 6.5
Sample 2 11.9 6.5 7.6
Sample 3 16.9 8 9.5
Sample 4 10.1 10 10.9

Calculation:

FFA= Titrate value X 2.82*

Weight of sample

2.82*: Oleic acid factor

Samples FFA value

Sample 1 0.28
Sample 2 0.29
Sample 3 0.25
Sample 4 0.25

Note: - Excessive boiling of oil may result in increased FFA value.

Results: The FFA value to the given sample of oil is within range so they can be used for
production of product inside the factory.

FFA for Fresh oil is = 0.25

FFA for used oil = 0.5

(B)Oxidation value (OV)

Aim: To estimate the oxidation value of the given oil sample.

Materials Required: Spectrophotometer, weighing machine, cuvette and oil sample.

26
Chemicals Required: Iso-octane, p-anasidine,

Procedure:

1. Take exactly 0.5g of oil sample A.

2. Take 25ml of Iso-octane, this is Blank A.
3. Set spectrophotometer wavelength at 350nm (for fresh oil).
4. Fill one cuvette with Blank A, i.e., iso-octane.
5. Auto zero the spectrophotometer with Blank A.
6. Then one cuvette with sample A.
7. This reading is to be taken as Ab*.
8. Take 5ml Iso-octane and 1ml p-anasidine, this is Blank B.
9. Take 5ml of sample and then after one min add 1ml p-anisidine. This is sample B.
10. Hold for 10mins.
11. Fill one cuvette with blank B
12. Auto zero the spectrophotometer with blank B.
13. Then run with sample B.
14. This reading is to be taken as As*.

Calculation:

Oxidation value = [(1.2 * As) - Ab] * 25

Weight of sample

As*: Absorbance of fat solution after reaction with p-anasidine.

Ab*: Absorbance of fat solution.

Precautions:

• Cover the test tubes with silver foil.

• Hold cuvette very carefully as it is too sensitive.

27
 (C) Peroxide Value (PV)

Aim: To check the peroxide value of the given oil sample.

Materials Required: Weighing machine, conical flask with stopper, heating plate, titration
apparatus and oil sample.

Chemicals Required: KI solution (Dissolve 4 part of pure potassium iodide in 3 parts of

distilled water, keep the solution in a brown bottle), PV solvent [acetic acid: chloroform=3:2],
starch solution, 0.01N Na2S2O3 (sodium thiosulphate) solution, distilled water.

Theory: Peroxide value (PV) states the mill equivalent of peroxide oxygen combined in a
kilogram of oil and able to liberate iodine from potassium iodide; iodine is the next estimated
using a standard sodium thiosulphate solution.

Procedure:

1. Take 5g of the given oil sample in a conical flask with a stopper.

2. Then add 30ml of PV solvent.
3. Then add 30ml distilled water.
4. Add 0.5ml KI solution and hold it for 1 min.
5. Then add 0.5ml of starch solution.
6. The solution obtains a blackish coloration.
7. Now titrate it against 0.01N Na2S2O3 solution.

End point of titration: Black colour disappears and the layers can be separated.

Calculation:

PV= Titrate value * normality of sodium thiosulphate/ Sample weight.

Observation: Peroxide values of fresh oils are less than 10 milliequivalents/kg; when
the peroxide value is between 30* and 40 milliequivalents/kg, a rancid taste is noticeable.

28
 5.TESTS FOR PRODUCTS

(a) Moisture Analysis

Aim: To estimate moisture percentage in the given sample.

Materials Required: Pestle and mortar, dish, hot air oven, permanent marker, desiccators, a
pair of tongs, spatula, weighing machine and the given sample to be tested.

Theory: Moisture content of foods may be determined:

(a) By drying in oven

(b) By distillation with an immiscible solvents
(c) By chemical and physical methods.

Procedure:

1. Take a dish and mark it using a permanent marker.

2. Now weigh the dish and note down its weight.
3. Crush the given sample using pestle and mortar.
4. Take between 8-10g of the crushed sample in the dish and note down the weight again.
This is the total weight.
5. Now keep the dish in the hot air oven for 2-3 hours.
6. After 2-3 hours take out the dish carefully from the hot air oven using a pair of tongs
and keep inside the desiccator for 4-5 minutes.
7. Now note down the final weight of the dish

Observation:

Sample Sample wt. Dish wt. (gm) Total wt. (gm) Wt. After
(gm) drying (gm)
Yellow banana 10.48 16.36 26.87 26.51
chips
Aloo sev 10.37 16.30 26.69 26.53
mixture
Butter popcorn 10.30 14.48 24.81 24.59

29
 Gupshup 10.93 15.86 26.80 26.62
peanuts

Calculation:

Moisture content = Total weight- Final weight * 100

Weight of the sample

Sample Moisture Content %

Yellow banana chips 3.43
Aloo sev crazy mixture 1.49
Butter popcorn 2.13
Gupshup 1.64

(b) Oil analysis

Aim: To estimate the oil content of the given sample.

Materials Required: Pestle and mortar, round bottom flask, thimble, permanent marker, a
pair of tongs, spatula, weighing machine, petroleum ether, soxhlet apparatus, given sample
product and hot air oven.

Theory: Ether soluble materials in a food are extracted from an oven dried sample using a
soxhlet extraction apparatus. The ether is evaporated are the residue is weighed. The ether
extracted crude fat of a food represents, besides the true fat (triglycerides).Other materials such
as soluble materials are not extracted since the sample has been thoroughly dried prior to
extraction with anhydrous ether or petroleum ether.

Procedure:

1. Take a round bottom flask and mark it with a permanent marker.

2. Now weigh it and note down its weight.
3. Crush the given sample using pestle and mortar.
4. Take 8-10g of the crushed sample in the thimble.
5. Then filled three-fourth of the round bottom flask with petroleum ether.

30
 6. Now keep the thimble inside the thimble holder in the soxhlet apparatus for about 4-
5hrs.
7. Set the temperature of the soxhlet at 300C.
8. After 4-5hrs take the round bottom flask out of the soxhlet apparatus and keep it inside
hot air oven using a pair of tongs so as to volatize the petroleum ether.
9. Now note down the final weight of round bottom flask.

Observation:

Product name Wt. of sample in Initial wt. (gm) Final wt. (gm)
thimble (gm)
Pudina sev 10.93 97.41 101.29
Crazy mixture 10.48 93.74 97.33
Yellow Banana 10.62 106.72 110.42
chips
Tangy tomato 10.44 97.46 101.92
banana chips
Soya chips 10.59 107.12 111.33
Spicy banana chips 10.21 98.67 102.84

Calculation:

Oil%= Final weight – Initial weight * 100

Weight of the sample

Product name Fat %(STANDARD)

Pudina sev 35.49
Crazy mixture 34.25
Yellow banana chips 34.83
Tangy tomato banana chips 42.72
Soya chips 39.75
Spicy banana chips 41.03

31
Result: The given sample have appropriate amount of oil which match the standard of the
company.

(C)Acidity%

Aim: To test the percentage of acid in the given sample product.

Materials Required: Weighing machine, conical flask, pestle mortar, dish, distilled water,
titrating apparatus and the given sample.

Chemicals Required: N/20 NaOH Solution, 1% phenolphthalein indicator.

Theory: Food acidity is the important factor besides affecting flavor. Food acidity affects the
ability of microorganism to grow in the food. Microorganism prefers minimal acidity and is
prevented from growing when acid level gets high enough. Titrable acidity of a solution is an
approximate of solution total acidity. The titrable acidity of the solution is measures by reacting
acid present with base such as sodium hydroxide to a chosen end point, close to neutrality, as
indicated by an acid sensitive color.

Procedure:

1. Take X gram of the given sample and crush it well using pestle and mortar.
2. Transfer the crushed sample in the conical flask and add 100ml of distilled water to it.
3. Now add few drops of 1% phenolphthalein indicator.
4. Titrate it against N/20 NaOH solution.

End point of titration: Permanent light pink colour is obtained.

32
Observation:

Product name Weight of sample (gm) N/20 NaOH

consumed

Initial Final
Cheese balls masala 0.19 0 0.8
Thin fries masala 0.19 0.8 2.9
Punjab tadka masala 0.20 2.9 5.7
Mast masala 0.16 5.7 7.4
Pudina chips masala 0.18 7.4 9.1
Diet mixture 0.24 9.1 9.2
Popcorn 1.46 9.2 9.5

Calculation:

Acidity%= [Final titrate value- Initial titrate value] * 0.32

Weight of the sample

(OR)

Acidity%= Titrate value * ‘N’ of NaOH * equivalent weight of traceability

Weight of sample

X= 0.15-0.20g for masala and 1-2g for product.

Product name Acidity %

Cheese ball masala 1.34
Thin fries 3.5
Punjabi tadka 4.97
Mast masala 1.34
Pudina chips masala 3.02

33
 Diet mixture 0.13
Popcorn 0.06

(d) Salt%

Aim: To test percent salt in the given sample product.

Materials Required: Conical flask, pestle and mortar, dish, distilled water, titrating apparatus
and given sample product.

Chemicals Required: N/10 AgNO3 solution, 5% potassium chromate.

Theory: The addition of standard AgNO3 (silver nitrate) to sample solution, using K2CrO4
(Potassium chromate) as the visual indicator, yields an insoluble precipitate which is
proportional to the amount of total chlorides in the solution. The red colored silver chromate
complex, formed by the combination of AgNO3 and K2CrO4 is soluble in acid and losses its
color. The salt content of the sample may be calculated from the value of saturated AgNO3
used to reach the end point the chemical reactions is:

AgNO3 + NaCl = NaNO3 + AgCl

When all the AgCl has been precipitated, yellow–orange color appears which denotes the end
points. This color is the results of the formation of a second precipitate (AgCrO4) as shown in
equation:

2AgNO2 + K2CrO4 = AgCrO4 + 2KnO2

Procedure:

1. Take X gram of sample and crush it using pestle and mortar.

2. Transfer the crushed sample to the conical flask and add 100ml distilled water to it.
3. Now add few drops of 5% K2CrO4 indicator.
4. Titrate it against N/10 AgNO3 solution.

End point of titration: Reddish brown or brick red colour persists.

34
Observation:

Product name Weight of sample (gm) AgNO3 consumed

Initial Final
Cheese balls masala 0.19 0 4.9
Thin fries masala 0.19 4.9 15.3
Punjab tadka masala 0.20 15.3 24.4
Mast masala 0.16 24.4 32.0
Pudina chips masala 0.18 32.0 40.1
Diet mixture 0.24 40.1 41.2
Popcorn 1.46 41.2 45.6

Calculation:

Salt% = [Final titrate value- Initial titrate value] * 0.5845

Weight of the sample

X= 0.15-0.20g for masala and 1-2g for product.

Product name Salt %

Cheese ball masala 15.07
Thin fries 31.99
Punjabi tadka 29.54
Mast masala 27.76
Pudina chips masala 26.30
Diet mixture 2.67

35
 CLEANING AND SANITATION

1.) Program for waste Disposal

Purpose:
To ensure, design and construct the establishment in a way so that there is no
cross connection between the sewage system and any other waste effluent system
in the establishment and they do not pass directly over or through production areas
unless they are controlled to prevent contamination. These systems are equipped
with functional traps and vents which do not emit odour .
To maintain and provide adequate facilities equipment and containers that are
clearly identified ,leak proof and where appropriate, covered are provided and
maintained for the storage of waste and inedible material prior to removed from
the establishment. Waste is removed and facilities and containers are cleaned and
sanitized at an appropriate frequency to minimize contamination.

Frequency: Monthly within the first week.

Responsibility: QA Technician ,QA Manager and Maintenance Supervisor or

Designate.

Procedure:

1.The compliance to the reference standards shall be monitored by conducting a

building inspection. This involves touring the company’s exterior premise and the
roof and performs a visual inspection to ensure compliance to all policies and
company standards. The accuracy of the company floor plans and site plans shall be
verified during the building inspection.

2.The following shall be observed :

a.)All water installations and equipment shall be constructed and maintained to

prevent back siphon age and backflow.

b.)The sewage disposal system shall be adequate for the process and shall be
maintained to prevent either direct or indirect contamination of food.

c.)Only plastic garbage cans which can vary in sizes and color shall be used in the
production ,packing and warehouse area to store waste or inedible material prior to
removal. Plastic garbage bags should be used to contain the waste in the garbage can.
d.)All waste and inedible material shall be emptied into the garbage dumpster in the
parking lot of the exterior premise.

e.)All waste and inedible materials shall be removed from the building daily.

f.)The exterior garbage dumpster shall be emptied weekly or when full

36
g.)Inedible material (recycle plastic ,cardboard, construction material) shall be
compiled neatly adjacent to the garbage dumpster while awaiting removal or
recycling.

h.)The exterior garbage dumpster shall be located at the furthest distance away from
the manufacturing plant.

i.)All garbage cans shall be cleaned and sanitized daily.

j.)The main garbage bin shall be cleaned and sanitized regularly or when dirty.

3.)All observations shall be record on the building inspection report .(signed and
dated)

4.)If the maintenance supervisor or QA Manager is unable to conduct the inspection

,then an assigned QA Technician or the Maintenance Technician shall conduct the
inspection and record all finding in the building inspection report.

5.)Any non compliance issue leading to a risk in food safety and pest activity shall be
documented on the building inspection report or QA checklist and appropriate forms.
Deviation/corrective actions shall be discussed jointly between the maintenance
Supervisor and the QA Manager.

6.)Any immediate corrective actions taken or to be taken shall be documented in the

building inspection report and QA checklist and appropriate forms.

7.) If food safety has been compromised the product is held tested and subsequently
released, reworked or destroyed and recorded on the corrective action report .Records
include a description of the deviation ,the corrective actions are developed by
performing a root cause analysis describing the preventive measures ,date for
completion and person responsible and is recorded on the corrective action report.

8.) Once every year the Food safety Team /president/Unit Head observes the
Maintenance Supervisor and the QA Manager in the performance of their monitoring
function and reviews all records that have been completed since the last verification.
All Building Inspection Report records are signed and dated by the Unit head
/President at the time of verification.

9.) If deviations are encountered during the verification process, where the building
inspection program is not maintained to a satisfactory level. the food Safety
Team/President /Unit Head shall review the cause of the concern with the QA
Manager and Maintenance Supervisor to determine whether food safety has been
compromised and recorded on building inspection report .If food safety has been
compromised the product is held, tested and subsequently released reworked or
destroyed and recorded on the Corrective action Report. Appropriate corrective
actions shall be developed by performing a root cause analysis, describing the

37
preventative measures, date for completion and personnel responsible assigned and
recorded on the Corrective action report.

RECORDS:

Building inspection report

Corrective action report

Factory Floor Plan

Outside Contractors Service

2.)Program for washrooms and cleaning facilities-

Purpose:

The purpose of this program is to ensure that:

i.) Washrooms have potable running water, soap dispensers, soap ,sanitary hand
drying equipment or supplies and a cleanable waste receptacle. Hand washing
notices are posted in appropriate areas.
ii.) As required , wash rooms, lunch rooms and change rooms are provided with
adequate floor drainage, ventilation and are maintained in a manner to prevent
contamination. They are separated from and do not open directly into
processing areas.
iii.) Equipment cleaning and sanitizing facilities are constructed of corrosion
resistant materials capable of being easily cleaned and are provided with
potable water at temperatures appropriate for the cleaning and sanitizing
chemicals used. They are adequately separated from food storage, processing
and packaging areas to prevent contamination.
iv.) Cleaning and sanitizing equipment is designed for its intended use and is
properly maintained.

Responsibility: QA Technician, QA Manager and Maintenance Supervisor or

designate

Frequency: Monthly within the first week.

Procedure:

1.) The compliance to the reference standards shall be monitored by conducting a

building inspection. This involves touring the company’s interior premise and
performs a visual inspection to ensure compliance to all policies and company
standards. The accuracy of the company floor plans and site plans shall be verified
during the building inspection.

2.) The following shall be observed:

38
 a.) Washrooms have potable running water, soap dispensers, soap, sanitary hand
drying equipment or supplies and a cleanable waste receptacle with sufficient capacity
and kept clean. Hand washing notices are posted in appropriate areas.

b.) Washrooms, lunchrooms and change rooms are provided with adequate floor
drainage, ventilation and are maintained in a manner to prevent contamination. They
are separated from and do not open directly into processing areas.

c.) Washrooms, lunchrooms and change rooms are identified on building plan. Plans
must show adequate separation from processing rooms.

d.) Equipment cleaning and sanitizing facilities are constructed of corrosion resistant
materials capable of being easily cleaned and are provided with potable water at
temperatures appropriate for cleaning and sanitizing chemicals used. They are
adequately separated from food storage, processing and packaging areas to prevent
contamination.

e.) Equipment specifically used for cleaning and sanitizing need to be described and
listed. Are there any criteria to describe maintenance and condition of this equipment
.Also include the need to ensure that it is used as intended (designated brooms,
brushes etc) and effective in cleaning without contamination.

3.) All observations shall be recorded in the building inspection report.

4.) Rest the same events is followed as described above in the waste disposal
procedure numbered 4,5,6,7,8,9 and maintained.

3.)Program for water used premises-

Purpose-

The purpose of this program is to assure that:

i.) Water is analyzed by the company at a frequency adequate to confirm its

portability. Water from sources other than the in house RO unit or municipal
supplies shall be treated as necessary and tested to ensure portability. Water
portability records include: water source sampling site, analytical results,
analyst and date .Water meets the requirements of IS 4251:1967 water for
processed food industry.
ii.) There are no cross connections between potable and non potable water
supplies and clear cut demarcation is done in between the potable and non
potable lines.
iii.) All hoses ,taps or other similar sources of possible contamination are
designed to prevent back flow or back siphon age.

iv.) The volume, temperature and pressure of the potable water/steam are adequate
for all operational and clean up demands.

39
 iv.) Where it is necessary to store water, storage facilities are adequately
designed, constructed and maintained to prevent contamination e.g covered
and cleaned up periodically. The water storage facilities shall be cleaned
periodically. The water storage facilities shall be periodically sampled to
ensure no contamination.

vi.) Re circulated water is treated, monitored and maintained as appropriate for the
intended purpose and has a separate distribution system which is clearly identified.
The re-circulated water and water changes shall be sampled to ensure no
contamination.

Responsibility: QA Technician,QA Manager and Maintenance Supervisor designate.

Frequency: Monthly within the first week

. Procedure:

1.) A.) Take sterilized (121˚C for 15 min) bottles; label with the date and “water
sample”

Flame the tip of the tap using spirit.

Run the hose/taps used for production for 5 minute and then take a sample.

Repeat at another random location.

Send sample to lab for testing.

If testing is to be carried out after 3 hours the sample bottle must be kept in ice.

Parameters are as follows: TPC <50 cfu/ml at 37˚C.

Total coliforms: absent in 100 ml (MPN); Not more than 2 positive consecutive
tests.

Similarly the samples may be sent to outside lab at six months interval.

B.) All chemicals shall have food grade approval and be documented on the list of approved
chemicals.

C.) Survey the interior building to ensure there are no cross connections between potable and
non potable water supplies.

D.) Building inspection is to be conducted to verify the accuracy of the company floor plans
and site plans and all observations are recorded in building inspection report.

E.) The sanitation supervisor shall take the temperature of water used during clean up and
record on the pre operational checklist. Ensure the volume, temperature and pressure of the
potable water/steam are adequate for all operational and cleanup demands. List out criteria to
outline how they are being maintained during use.

40
F.) a.) Interior building plan identifies location of storage tanks associated with water used
during processing or sanitation.

b.)Water storage facilities are adequately designed, constructed and maintained to prevent
contamination e.g covered

c.)Potable water sampling programs (e.g micro sampling) takes place once six monthly to
ensure no contamination.

G.) a.) If applicable, re-circulated water is treated, monitored and maintained as appropriate
for the intended purpose and has a separate distribution system which is clearly identified.

b.) Re circulated and treated water sampling (e.g micro sampling) takes place once annually
to ensure no contamination.

2.) The QA Manager will review, initial and date the water analysis certificates from the
outside lab.

3.) Any non –compliance issue leading to a risk in food safety and pest activity shall be
documented on the Building inspection Report or QA check list and appropriate forms.
Deviation /corrective actions shall be discussed jointly between the maintenance supervisor
and the QA Manager.

4.) Any immediate corrective actions taken shall be documented in the building inspection
Report and QA checklist and appropriate forms.

5.) Rest the same events is followed as described above in the waste disposal procedure
numbered 7, 8, 9 and maintained

Records:

Corrective action report.

List of approved chemicals.

Building Inspection Report

Plant and Personal Hygiene Record

Water testing reports.

41