INDUSTRIAL INTERNSHIP REPORT

AT MONDELEZ INDIA FOODS PRIVATE LIMITED

Hadbast No- 199, Village- Sandholi, Baddi
Tehsil- Nalagarh, Solan, HP- 173205

Submitted to: Submitted by:

Dr. Y.S Dhaliwal Akshay Deepak

Head Of Department B.Tech 4th Year

Department Of Food Science, Nutrition & Technology H-2014-05-005

College Of Home Science

CSKHPKV Palampur (HP) 176062

 CONTENTS

 Introduction of Company

 Baddi Manufacturing Plant

 Training Schedule

 E-4 Processing

 Special Learning

 Project Report
1. Introduction of Company:

1.1 History:

1.1.1 Mondelez:
Mondelez International is an American multinational confectionery, food, and Beverage
Company based in Illinois which employs about 107,000 people around the world. It consists of
the global snack and food brands of the former Kraft Foods after the October 2012.
The Mondelez name, adopted in 2012, was suggested by Kraft Foods employees and is a
combination of the words ‘Monde’ and ‘delez’. “Monde” derives from the latin word for
“WORLD” whereas, “delez” is a fanciful expression of “DELICIOUS”.
The company’s headquarters is in the Chicago suburb of Deerfield, Illinois, manufactures
chocolate, biscuits, gum, confectionery, and powdered beverages. The company has an annual
revenue of about $30 billion and operates in approximately 165 countries.

Mondelez India Foods Private Limited is a part of the Mondelēz International group of
companies and is in the business of creating delicious moments of joy – by producing delectable
chocolate confectionaries, gum and candy products, and popular beverages and foods that
include many of India's most popular and trusted food brands.

Mondelez teams believe in one thing – something that’s unique to them – and that is “The
Power of Big and Small”.

Mondelez’s brand Cadbury Dairy Milk (CDM) is considered the "Gold Standard" for chocolates -
the pure taste of CDM defines the chocolate taste for the Indian consumer. Other much loved
brands include Cadbury Bournvita, CDM Silk, Cadbury Choclairs, Gems, 5-Star, Perk, Bournville,
Celebrations, Halls, Éclairs, Bubbaloo, Oreo and Tang.

Mondelez India Foods Private Limited is a part of Mondelēz International, the global snacking
and Food Company and a spin-off from Kraft Foods Inc. Mondelēz International is the world's
largest chocolatier, biscuit baker and candy maker, and the second-largest maker of gum.

Mondelez India Foods Private Limited has been in India for over 6 decades, having started in
1948 as an importer of chocolates. Their work ethic, values systems and quality standards make
them an employer of choice in India. Their large community extends into India's agricultural
spaces. Since 1965, Mondelez India Foods Limited has pioneered and enhanced the
development of cocoa cultivation in India. For over two decades, they have worked with the
Kerala Agricultural University to undertake cocoa research and improve cocoa yields. Their
cocoa team works with farmers to improve incomes through best practices in all aspects of
cocoa cultivation - from planting to harvesting. Their efforts have touched the lives of
thousands of farmers.

Figure 1- Mondelez International in India

Headquartered of Mondelez India Foods Private Limited is in Mumbai.The head office is
presently situated at Pedder Road, Mumbai, under the name of "Cadbury House". It has sales
offices in New Delhi, Mumbai, Kolkata and Chennai and manufacturing facilities at Thane, Induri
(Pune),Malanpur(Gwalior), Baddi (Himachal Pradesh) and Sri City (Andhra Pradesh).

1.1.2 Cadbury:
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 fifty countries worldwide. It is famous for
its Dairy Milk chocolate, the Creme Egg and Roses selection box, and many other confectionery
products.
Currently, Cadbury India operates in five categories – Chocolate confectionery, Beverages,
Biscuits, Gum and Candy.It is the market leader in the chocolate confectionery business with a
market share of over 70%.
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. 
In 2003, Cadbury dropped the 's' from its name and renamed the brand to Cadbury. The
company found that it was a much more suited, rounded name than the previous "Cadbury's".
This change was announced on 19 December 2002.
On 19 January 2010, it was announced that Cadbury and Kraft Foods had reached a deal and
that Kraft would purchase Cadbury for £8.40 per share, valuing Cadbury at £11.5bn
(US$18.9bn). Kraft, which issued a statement stating that the deal will create a "global
confectionery leader", had to borrow £7 billion (US$11.5bn) in order to finance the takeover.
On 4 August 2011, Kraft Foods announced they would be splitting into two companies
beginning on 1 October 2012. The confectionery business of Kraft became Mondelez
International, of which Cadbury is a subsidiary.
On 21 April 2014, Cadbury India changed its name to Mondelez India Foods Limited.
1.2 Different Brands of Mondelez:

Figure 2- Different Brands of Mondelez

Figure 3- Start-up year of different brands of Mondelez International

2. Baddi Manufacturing Plant:

Figure 4- Mondelez International, Baddi

Name of Plant:Mondelez India Foods Pvt. Ltd. (Formerly Cadbury India Pvt. Ltd.)
Location:Hadbast No. 199, Sandholi, Baddi
District:Solan
State:Himachal Pradesh
2.1 Products manufactured in the plant:
E1: Bourn vita, Bourn vita little champs
E2: CDM
E3: Cadbury Gems and Cadbury Five-Star
d
B
la
P
it
n
U
1
2
-
E4: Cadbury Dairy Milk (CDM) (Fruit & Nut, Roasted Almond, Crackle)
CDM Silk (Plain, Fruit & Nut, Roasted Almond)
E5: Crumb that is used for manufacturing of chocolate.

Figure 5- Different units of Baddi plant

Baddi manufacturing plant was setup in Sept. 2005. Now, production of CDM in E2 plant is
closed and only, refined milk chocolate (RMC) is prepared.

Unit

E1

E2

E3

E4
Production Starts in

2005

2006

2009

2009
 E5 2012
Table 1- Set-up year of different units of Mondelez International Baddi
2.2 Departments:
1) Procurement:

The purchase department handles all the purchases that happen in the organization from all
the departments (Manufacturing, Quality & food safety, Asset care, Administration, Human
resources etc.). The purchase department selects specific vendors for all the raw materials
based on certain criteria and then goes about doing the transactions in coordination with
the stores department and other departments.

2) Stores:

The stores department is responsible to receive and stock all that enters the organization
with a proper record of each and every single material. The stores department works in line
with the purchase department mainly and indents all that is being received. The stores
department then issues the stock (stored goods) to the respective as and when required. A
minimum stock of all the products has to be maintained in the stores department after
which it generates a procurement order which is sent to the purchase department which
would then do the needful.

3) Manufacturing:

The manufacturing department deals with the manufacturing of the products and the
related processes. This includes receiving orders/demands from the Marketing & sales
department which set the monthly targets for all the products. Depending on the monthly
production target set (goals), the manufacturing department gives in demands for raw
materials, packaging materials and other requirements to the stores department so that
they can avail all the materials in sufficient amount to achieve the production target. The
manufacturing department also takes care of the in-process products during the entire
chain of production from start till end and maintains a proper legitimate stock of goods at
each and every stage of the manufacturing process.

4) Quality & Food Safety:

The quality and food safety department deals with the online and offline monitoring of the
products being manufactured. This department also takes care of the quality compliance of
all the raw materials and packaging materials that are indented. All the raw materials and
packaging materials are analyzed as per the pre-set standard protocols and only then they
are approved. Until this is done, the stores department does not have the authority to issue
the materials to the manufacturing department for usage. In case, any of the material does
not meet the specified standards, it is rejected without any exception and is sent back to
the supplier. The quality and food safety department also handles the quality system and
the regulatory concerns of the plant and its products. The GMPs (good manufacturing
practices), FSMS (food safety management system) & Quality policies etc. that are in place
need to be practiced and followed throughout the entire manufacturing process without
fail.

5) Asset Care:

The asset care department handles the preventive maintenance as well as the post
breakdown repairing of all the mechanical, electronic and electrical components of the
entire plant. Regular preventive maintenance/servicing in specific time intervals need to be
done without fail to ensure a longer life of the equipment and machinery. Proper
functioning of all the utilities (steam, chilled water, chilled air, etc.) is also the responsibility
of this department.

6) Continuous Improvement:

This is a unique department which focuses on various improvement strategies and projects
in the industry. Various projects under the heads of Lean manufacturing, Six sigma,
Kaizens& 5S etc. are handled by this department mainly with inputs from all the
departments as and when required. Improvement of the present scenario of the plant and
proper efficient planning of the new installations etc. are the main responsibilities of the
continuous improvement department.

7) Human Resources:

The human resource department handles all the requirements and the workforce
management of the entire organization. Training of the newly joined employees as well as
regular training of the present employees of various departments and cadres is carried out
by the human resource department. Apart from this, the cafeteria arrangements,
arrangements of conveyance for the employees and other recreational activities are the
part of the human resource department’s activities.

8) Finance:
 The finance department handles all the financial interventions at various stages of the
organization like manufacturing, marketing, sales revenues, manpower etc. It deals with the
computation of the revenues of each and every thing happening in the organization. The
finance department also handles the tax related activities and the accountancy audits and
submissions required to be done with the government as and when required.

2.3 Organizational Chart:

 3.1 Activities Performed:
3. Training Schedule:
Figure 6- Organizational Chart
Assistan
Sr. t
Executive
Ma nage r o f
Manufact
SFCs (shop floor
Executive
Ma nage
Factory r o f
eague) of
leach
coluring
each each
department
Manager
dep
Managartm ent
er
dep artm ent
During the training program, following activities are done:

 Plant Safety Training.

 Induction, during which, we visited different sections of the plant.
 Learned about GMP (good manufacturing practices).
 Learned the detail manufacturing process of E-4.
 Conducted DMS (daily management system) meeting and hearing & resolving the
problems of operators.
 Quality testing of E4 Plant

3.2 Good Manufacturing Practices:

1) Prevention of metal contamination in the product

Banned items are:

 Metal staples staplers
 Pins & drawing pins
 Sewing needle
 Jewelry
 Knives not issued by the company
2) Prevention of glass contamination in the plant

Banned glass items are:

 All glass items from production area & associated areas including tear room,
store room and work shop
 Drinking, cooking & food serving utensils
 Food containers
 Picture frame
 Display cabinet
 Glass thermometer
 Thermo-flask
 Make up mirror
 Watches
 Jewelry

Maintenance & construction work requirement

Changing of lights, glass window or any glass component must be performed wherever possible
and then, the production area must be barrier off. Wherever temporary lighting is required for
maintenance or other reasons, it must be performed by only authorized person.
3) Cleaning and chemical control

Storage
 All containers containing chemicals must be correctly labeled all time.
 Chemicals must be stored correctly & away from the production area.

Chemical requirement

 Strong perfumed chemicals must not be used.

Lubricant requirement

 Where there is the potential for lubricants to contact with ingredients in process
material, finished product & packaging materials, these lubricants must be
classified as food or pharmaceuticals grade.
4) Housekeeping
 Sills must be cleaned up immediately.
 All doors to the external environment must be kept closed.
 Floors & windows must be in good conditions.
 There must be no foreign matter.
 Hand-wash station must be kept tidy with soap.
 Tool must be cleaned and in good state of repair.

Prevention of insect, rodent & bird infestation

 High standards housekeeping must be maintained at all times to minimize the

availability of food & water which may attract pests.
 Doors and windows must be closely fitted & any hole in the building fabrics
sealed.
5) Prevention of plastic contamination in the plant

Banned items are:

 Plastic ruler
 Plastic bags
6) Prevention of wood contamination in the plant

Banned items are:

 Wooden handled knives
 Use of wooden rods
7) Handling, storage & packing control
  All toxic chemicals including cleaning & maintenance compounds & almond
product related materials such as equipment’s parts must be completely
segregated from all food ingredients & packaging materials.
8) Prevention of foreign matter

Conveyor belt
 Belts must be specified installed & maintained to minimize the risk of possible
fraying.

Clothing

 System for the prompt repair & replacement of damaged must be available.

String

 Use of thread in production area must be controlled at all the times.

Cleaning bags

 Non-fiber based materials must be used in industry.

Paper, cardboard & tape

 Where the use of paper, cardboard & tape is identified, it must either replace &
removed with a suitably engineered solution.
 FOOD SAFETY AND QUALITY ASSURANCE

FOOD SAFETY:

Food safety is a scientific discipline describing handling, preparation, and storage of food in
ways that prevent food borne illness. These methods include a number of routines that should
be followed to avoid potentially severe health hazards. Safety should be maintained between
industry and the market and then between the market and the consumer. In considering
industry to market practices, food safety considerations include the origins of food including
the practices relating to food labeling, food hygiene, food additives and pesticide residues, as
well as policies on biotechnology and food and guidelines for the management of governmental
import and export inspection and certification systems for foods. In considering market to
consumer practices, the usual thought is that food ought to be safe in the market and the
concern is safe delivery and preparation of the food for the consumer.

Need for food safety:

 Food safety and hygiene are crucial to reducing the risk of food-borne illnesses that
may cause through biological hazards such as pathogenic bacteria, viruses, and
parasites, or chemical hazards or natural toxins.
 If the food safety guidelines are not followed precisely, people can fall sick and may
even lead to death.
 If the food is improperly stored, handled, cooked, or refrigerated, bacteria can grow
leading to food contamination.
 At times, there would be issues like product recall, where seller may request
consumers to return a product after the discovery of any product defects or safety
issues that might endanger the consumer or put the seller at risk of legal action
QUALITY ASSURANCE:

Quality assurance is any systematic process of checking to see whether a product or service
being developed is meeting specified requirements or standards. Many companies have a
separate department devoted to quality assurance. A quality assurance system is said to
increase customer confidence and company's credibility. Quality assurance systems emphasize
catching defects before they get into the final product.

Need for Quality Assurance:

 There is a need for an accurate, transparent system for monitoring the accuracy of
Research and their developments after release by the manufacturer.
 Quality assurance scheme is essential to ensure that test quality is maintained
 Quality assurance involves in improvement of the overall process through data
collection, problem trend analysis, process identification & process analysis.
DIFFERENCE BETWEEN QUALITY ASSURANCE AND QUALITY CONTROL:

Quality assurance is a part of quality management which is focused on providing confidence

that quality requirements will be fulfilled. The confidence provided by quality assurance is of
two ways internally to the management and externally to customers, government agencies,
regulators, certifiers, and third parties.

Quality control is that part of quality management which is focused on fulfilling quality
requirements. While quality assurance relates to how a process is performed or how a product
is made, quality control is more the inspection aspect of quality management.
 CHOCOLATE

Chocolate means a homogeneous product obtained by an adequate process of manufacture

from a mixture of one or more of the ingredients, namely, cocoa beans, cocoa nib, cocoa mass,
cocoa press cake and cocoa dust (cocoa fines/powder), including fat reduced cocoa powder
with or without addition of sugars, cocoa butter, milk solids including milk fat The chocolates
shall not contain any vegetable fat other than cocoa butter.

The material shall be free from rancidity or off odour, insect and fungus infestation, filth,
adulterants and any harmful or injurious matter.

The chocolates shall be of the following types:-

 Milk chocolates is obtained from one or more of cocoa nib, cocoa mass, cocoa press
cake, cocoa powder including low-fat cocoa powder with sugar and milk solids including
milk fat and cocoa butter.
 Milk Covering Chocolate - as defined above, but suitable for covering purposes.
 Plain Chocolate is obtained from one or more of cocoa nib, cocoa mass, cocoa press
cake, cocoa powder including low fat cocoa powder with sugar and cocoa butter.
 Plain Covering Chocolate-same as plain chocolate but suitable for covering purposes.
 Blended Chocolate means the blend of milk and plain chocolates in varying proportions.
 White chocolate is obtained from cocoa butter, milk solids, including milk fat and sugar.
 Filled Chocolates means a product having an external coating of chocolate with a centre
clearly distinct through its composition from the external coating, but does not include
flour confectionery pastry and biscuit products. The coating shall be of chocolate that
meets the requirements of one or more of the chocolate types mentioned above. The
amount of chocolate component of the coating shall not be less than 25 per cent of the
total mass of the finished product.
 Composite Chocolate-means a product containing at least 60 per cent of chocolate by
weight and edible wholesome substances such as fruits, nuts. It shall contain one or
more edible wholesome substances which shall not be less than 10 per cent of the total
mass of finished product.
 CHOCOLATES MANUFACTURED AT BADDI

1. CADBURY DAIRY MILK-REGULAR

It is a Milk chocolate with Ingredients sugar, FCMP, SMP, cocoa butter, cocoa liquor,
emulsifiers (426,476) nature identical & artificial [ethyl vanillin] flavoring substances. The
ingredients are mixed and then heated in conches to get the desired liquid chocolate. The
liquid chocolate is then deposited in moulds. It is manufactured as SKU 25.3g and 52g at the
Baddi site.

2. CADBURY DAIRY MILK-CRACKLE

It is a inclusion chocolate with Ingredients sugar, FCMP, SMP, cocoa butter, cocoa liquor,
emulsifiers (426,476) nature identical & artificial [ethyl vanillin] flavoring substances and
rice crisps as inclusion. It is manufactured as 36g SKU.

3. CADBURY DAIRY MILK-ROAST ALMOND

It is a inclusion chocolate with Ingredients sugar, FCMP, SMP, cocoa butter, cocoa liquor,
emulsifiers (426,476) nature identical & artificial [ethyl vanillin] flavoring substances and
roasted almonds as inclusion. It is manufactured as 36g SKU.

4. CADBURY DAIRY MILK-FRUIT AND NUT

It is a inclusion chocolate with Ingredients sugar, FCMP, SMP, cocoa butter, cocoa liquor,
emulsifiers (426,476) nature identical & artificial [ethyl vanillin] flavoring substances and
cashew, raisins and almonds as inclusion. It is manufactured as 36g SKU.
 5. GEMS :It is a confectionery type product. The chocolate prepared is dropped in dies
and then the beans are coated with gums, wheat flour and color. The gems packs are
3.56g, 8.9g, 17.8g SKU.

6. FIVE STAR:It is a composite chocolate with inner layer of caramel and nougatine
coated with chocolate. It is manufactured as 10g, 10.1g, 19.5g, 40g SKU.

7. CADBURY DAIRY MILK SILK

It is a Milk chocolate with Ingredients sugar, FCMP, SMP, cocoa butter, cocoa liquor,
emulsifiers (426,476) nature identical & artificial [ethyl vanillin] flavoring substances. Milk
fat is added in the chocolate preparation and the particle size is smaller than the plain
Cadbury dairy milk. The ingredients are mixed and then heated in conches to get the
desired liquid chocolate. It is manufactured as SKU 40g, 60g and 150g with an additional
250g (valentines) at the Baddi site.

8. CADBURY DAIRY MILK-ROAST ALMOND

It is a inclusion chocolate with Ingredients sugar, FCMP, SMP, milk fat, cocoa butter, cocoa
liquor, emulsifiers (426,476) nature identical & artificial [ethyl vanillin] flavoring substances
and roasted almonds as inclusion. It is manufactured as 55g and 137g SKU.

9. CADBURY DAIRY MILK-FRUIT AND NUT

It is a inclusion chocolate with Ingredients sugar, FCMP, SMP, cocoa butter, cocoa liquor,
emulsifiers (426,476) nature identical & artificial [ethyl vanillin] flavoring substances and
cashew, apricots and raisins as inclusion. It is manufactured as 55g and 137g SKU.
 MAJOR INGREDIENTS IN CHOCOLATE MANUFACTURE

1. COCOA POWDER/ COCOA LIQUOR

It means the powder which is the partially defatted

product derived from the cocoa bean the seed of
Theobroma cocoa

Role of cocoa powder in chocolate-

 It gives chocolate flavor

 It gives dark color’
 It develops aroma
 It gives textural properties
 Act as a leavening agent

2. SUGAR

Sugar is the generic name for sweet,

soluble carbohydrates, many of which are used in food.
In the body, sucrose is hydrolyzed into the simple sugars
fructose and glucose.

Role of sugar in chocolate-

 Provides sweetness
 If brown, provides color and texture
 Large amounts prevent micro-organism
 Caramelizes to produce a brown color
 Retains moisture
 Helps to trap air in cake mixtures
 Provides carbohydrate

3. MILK POWDER

It means the product obtained by partial removal of water from milk of Cow and / or Buffalo.
The fat and / or protein content of the milk may be adjusted by addition and/ or withdrawal
ofmilk constituents in such a way as not to alter the whey protein to casein ratio of the milk
being adjusted.

In chocolate there are two types of milk powders are used

1. Skimmed milk powder 2. Whole milk powder

Role of milk powder in chocolate-

Of the properties, the free milk fat available to mix with the cocoa butter in the chocolate and
the particle characteristics are arguably the most important. The level of free milk fat
influenced the tempering conditions needed to ensure proper crystallization of the cocoa
butter in chocolate. The free milk fat level also had a significant influence on rheological
properties, with lower viscosity and yield stress of the melted chocolate and generally reduced
hardness of the finished chocolate as free milk fat increased. Bloom inhibition was generally
related to free milk fat level, where chocolates made with higher free milk fat levels had greater
bloom stability.

4. FAT

In chocolates, generally following types of fats are used as shown below

1. Cocoa Butter

It is the fat obtained by expression from the nibs of the

beans of Theobroma cocoa L. Characteristics as follows

 Pale yellow liquid

 Characteristic flavor of chocolate
 Brittle at temperature below 25°C
 Softens in hand and melts in mouth (34°C)
 Not greasy to touch
  Keeps well due to presence of antioxidants
 Rich in saturated fatty acid

2. Milk Fat

It is the fatty products derived exclusively from milk and/ or products obtained from milk by
means of process which result in almost total removal of water and milk solids not fat.

Role of fat in chocolate-

 Provide flavor
 Keep products moist and extend shelf-life
 Add color to foods
 Make pastry 'short' by coating the flour to stop gluten developing
 Hold air when creamed with sugar
 Oil forms an emulsion with liquids (for example, mayonnaise)
 Provide energy and Vitamins A and D

6. WHEY POWDER

It is the product obtained by spray or roller drying sweet whey or acid whey from which major
portion of milk fat has been removed.

Role of Whey Powder in chocolate-

 It gives clean taste

 It improves texture
 It increases shelf life
 It increases protein content

7. FILLINGS

Chocolates are filled with various fillings to give extra taste and flavor. These fillings are nuts
and crisps. Some of them are mentioned below

 Almonds
 Nuts mixture
 Cashews
 Raisins
 Rice crisp
4. Section-wise Report:
4.1 E-4 Processing:
4.1.3 Process Description:

The raw materials for finished product manufacture are crumb, cocoa butter,
emulsifiers (Yolkin& PGPR) and flavours (C101, C201, EV-CDM mix) and inclusions
(For CDM F& N- sugared raisins, roasted cashewnuts, roasted apricot kernels; For CDM
RA- roasted almonds; For CDM Crackle- rice crispies, NBS pieces).

Crumb (oven / T reactor crumb) and cocoa butter are mixed well in a paste mixer to form a
paste. It is then passed through refiners- 2 roll refiner followed by 5 roll refiner, to form
Refined Emulsifiers and flavors are added at this stage. LMC is stored in storage tanks
before it is passed through temperor. The tempered chocolate is then deposited in
moulds, which are then passed through cooling tunnel to allow the bars to set. The
bars are then demoulded and packed in laminates to obtain finished product.

For CDM variants tempering is done in open temperor. When

chocolate temperature attains 30º C - 31º C in temperor, inclusions are added, mixed
and then deposited in mould.

 CRUMB DUMPING

· This is the place where crumb is dumped into silos .Crumb is a mixture of ingredients
Mondelēz use for the production of chocolates.
· Crumb is of 3 types: - 1. Oven crumb
2. Extended crumb
3. T-reactor crumb

· Crumb consists of simple ingredients like cocoa, whey powder, SMP, FCMP/WCMP.
· The crumb is hanged to dump with the help of gravity into the silos.
 · This crumb is dumped in silo tanks.

 PSM

· PSM stands for paste mixer.

· This is the unit in which the crumb is mixed with butter.
· Till now the crumb is in dry form, PSM makes this dry /powdered form of crumb into a
paste.
· This equipment helps in the further processing of chocolate making it easy to flow and
movement.

 ROLLLERS

These rollers are used to pulverize and dry out the paste mixing properly.
The plant uses two types of rollers:-

1. 2RR

2. 5RR

 2 ROLL REFINER
 Refining reduces the particle size. Two roll refiners is a drum roller which consists of 2
rolls rotating at their axis, opposite to each other. Shear force applied through nipping
the material between two rollers. Top roller moves at double the speed of lower roller.
Temperature of both rollers should be same and water is circulated inside rollers to
maintain the desired temperature. Particle sizes of the paste are reduced to less than
270 µm. Now, refined material is passed through belt conveyor to 5 roll refiner.

 5 ROLL REFINER

 5 roll refiners is also a drum dryer which consist of 5 rolls. Each roller has different
temperature and each are rotating at their axis opposite to each other. Shear force
applied through nipping the material between two rollers at a time. Initially, material
is fed between the first & second roller. Particle sizes of the paste are reduced to less
than 25 µm. The speeds of successive rolls are increases so that pastes are moving
forward. Each roller has double the speed of the roller below it. The product
obtained is known as RMC (refined milk chocolate). Now, refined material is passed
through steel belt conveyor to conch. Total time taken by 2 roll & 5 roll refiner for
passing one batch (1300 kg) is 60 min.
CONCH
 Conching process is responsible for coverting the refined chocolate into liquid chocolate.
Conch is jacketed and hot water at 55̊ C or steams are used for maintaining the
temperature. Agitator is there inside the conch for mixing & scraping the
surface.Conching process involves filling, dry conching, pasting, liquefying, mixing,
inspection & discharge. There are three conch for chocolate manufacturing in cdm. The
capacity of each conch is 1300 kg.

· Till now the chocolate was in dry form and cannot be consumed as such and unacceptable
to the consumer.
· The chocolate is made in liquid form with the help of conchs.
· Till now it is known as RMC which stands for refined milk chocolate.
· Conchs convert RMC in LMC or liquid milk chocolate.
· Conchs involve 7 different steps in process:-
1) FILLING –This step involves the dumping of refined milk chocolate into the conch.
2) DRYING-This step involves drying at high temperature with the lid of conch
opened ,which enables removal of water and also the unwanted aroma is leached
out.
3) PASTING-In this step Yolkin, and Butter is added to the conch, Yolkin is emulsifying
agent which help in the better mixing of butter.
4) LIQUIFY-In this step Yolkin, PGPR and Butter is added to the conch so the chocolate is
now in liquid form.
5) MIXING- This is the most crucial step of all, in this step the flavor is added to
theconch which is kept top secret by the company.
6) INSPECTION- After the addition of flavor the LMC is subjected for inspection.
7) DISCHARGE – After the inspection the liquid milk chocolate is subjected to discharge
in liquid milk chocolate storage tanks.
 SIEVE

· Now the liquid milk chocolate is transported to sieves from conch which enables its
filtration reducing its size and also avoiding the larger molecules which can cause
sardines in chocolate.

· The sieve used in this is of mesh size 40.

·

 STORAGE TANK
· After the filtration the liquid milk chocolate is fed to the storage tank.
· In this tank the temperature of chocolate is increased to release the flavors and achieve
desired aroma.
· Chocolate is discharged to the service tank from the storage tank.
· This tank is useful when the production is in bulk while the demand shortens.
· This tank helps in preventing wastage of chocolate during manufacture and helps to
keep the process continuous.
 TEMPERATURE REGULATOR

· When the chocolate is stored in service tank it is at a temperature of around 50°C.

· This temperature is not favorable for the manufacture procedure that’s why it is
dropped to a level of 32°C with the help of this machine.
· This ensures the high shelf life of the chocolate and also improves its texture.

 TEMPERING

 Temper is the property of the liquid chocolate to solidify in the correct crystalline form
to give the solid chocolate its characteristic gloss and structure. A tempered chocolate is
one which contains the correct quantity of solid cocoa butter, having the desired crystal
form in proportion to the liquid cocoa butter.
 Post-conching, the liquid chocolate is stored in jacketed storage tanks at a desired
temperature (typically ~ 45 ºC -50 ºC). All the recycled chocolate stream is then
passed through a detemperer / Heat exchanger before add back into the storage
tank. In detempering, the chocolate temperature is increased beyond 42°C, so as to
ensure that there are no fat crystals and all the fat is in molten state. The de-tempered
liquid chocolate then passes through a Temperor, which is also a heat exchanger that
cools the chocolate to around 29±0.5 °C. Again re-heating of it to around 31 °C
to convert the cocoa butter to the most stable form. Proper tempering ensures
problems related to snap, demoulding and fat bloom are minimized.

 DEPOSITOR

 From the depositor the chocolate is fed into the molds which are on a moving conveyer
belt.
 These molds are lead into a cold tunnel which have a series of vibrators, which is used
for the proper settling of the chocolate into the mold.
  Till the chocolate is fed into the mold it have a temp of around 30°C,which is dropped to
7-10°C in this tunnel.
 This tunnel can use 1080 molds at a single time and has 14 rows.
 The molds can be of different sizes and shapes.
 It consists of 22 vibrators which ensure proper settling of chocolate.
 The molds are moved in a zig- zag motion with a decrease in temperature along the
movement of belt.
 The temperature of the tunnel is kept at 7°C.

 MOLDING TUNNEL
· This is the tunnel which consists of many sub parts i.e. Temperature regulator,
depositor, vibrator etc.
· This machine is used for the deposition of chocolate and giving it a proper shape and
size.
· For shapes molds are used which can be of different shapes and sizes.
· From the service tank the chocolate is at a temperature of 31.5°C.
This chocolate is now fed to depositor which is a hooper consisting of a rotating flap which
helps to stop the production of lumps, during the deposition.

ADS AND METAL DETECTOR

ADS distribute the rows of bars to feed the packing machines in a systematic manner. It works
with the help of number of sensors. The pivot receives the signals from the modules and then
feed the row of bars to that empty module and further the module feeds the packing machines
Metal detector is the CCP here which works on detection- rejection mechanism. If it detects a
metal piece in a chocolate, it automatically rejects that chocolate. It is to be checked every 2
hours

 WRAPPING

 The wrapping is done with the help of auto wrapper machine.

 It uses high speed photo snapper equipment for packaging of chocolates.
 This is flow pack type folding machine.
 Its output is 420 bars of chocolate per min.
 In a day it can produce as much as 3 lakh bars.
 It seals and cuts off the chocolate bare automatically at a very high speed.
  It is semi-automatic machine in which the packaging rolls are changed as per the need of
the process.
Packing machines:

 PACKING
· After the wrapping the chocolates are hand packed into boxes.
· These boxes are moved by overhead conveyer belts.
· With the help of these belts the boxes are fed to the taping zone where the boxes are
taped.

· These sealed boxes are placed in carton boxes and sealed.

· These carton boxes are palletized and shipped to the desired place.

Secondary Packing

· Strips of packet or single packets are filled in C-Box manually and weighing is done
according to the specified weight of C-Box. Then, it is manually loaded on roller conveyor
of Taping & Coding Machine. One side taping of C-Box is done manually while, other side
is done in taping machine. BOPP (Bi-axially Oriented Poly-Propylene) tape is used for
taping purpose. Coding on C-Box is also done in this machine. Now, Packed C-Boxes are
kept on pellets manually. Stack height of C-Box is up to 4.

· Ware-house and Dispatch

Pellets are arranged on the floor according to 5S. Samples of each machine are collected
at regular interval and Seal integrity, Short count, Proper code, Size & Shape of beans,
 Quality of beans etc. are checked. If all are ok, then finished goods are sent to
warehouse for storage. It is stored in warehouse at least 3 days. After 3 days from
packing, it goes for sensory analysis. Sensory analysis is done by a group of authorized
person within the plant. If sensory is ok, it is ready for dispatch.

 REWORK

 While the packaging is done there is ample amount of chocolate bar which are not
packed due to any reason, that chocolate is not left for wastage instead that chocolate is
reused for the production of chocolate.

 That chocolate is taken by the rework conveyer and melted and reused to make bars
again.

5. Special Learning:
5.1 IL6S (Integrated Lean Six Sigma):
IL6S is based on a combination of well-known methodologies i.e. Lean, Six sigma, Total
productive maintenance &High performance organization.

IL6S is a build strategy. IL6S is a ‘step by step’ and ‘phase by phase’ journey.IL6S is not more
work; it is a different way to do work. Its working strategy is mainly divided into four ways:

1) Lean: Waste elimination capability

 8 Waste
 Kaizen
 OPL (one point lesson)
 RCA (root cause analysis)
 5S
2) Six sigma: Process capability
 Kaizen
 OPL
 RCA
3) TPM (total productive maintenance): System capability
 11 Pillars
 RCA/OPL
 Kaizen
 5S
 Visual management
4) HPWS (high performance working system): People capability
 System capability
 Kaizen

IL6S means 100% employee involvement, Zero incidents, Zero defects & Zero losses.

Safety – Quality – Delivery – Cost – Sustainability – Morale

5.2 IL6S Pillars:

There are total 11 pillars in IL6S that helps to implement the integrated lean six sigma
approaches in each & every department of plant. These are:

1) Leadership Pillar
2) Organization Pillar
3) Autonomous Maintenance (AM) Pillar
 4) Progressive Maintenance (PM) Pillar
5) Focused Improvement (FI) Pillar
6) Education and Training (E&T) Pillar
7) Work Process Improvement Pillar
8) Quality Management (QM) Pillar
9) Initiative Management (IM) Pillar
10) Safety, Health and Environment (SH&E) Pillar
11) Supply Network (SN) Pillar

Traditional Batch Lean Manufacturing

Manufacturing
Orientation Supply driven Customer driven
Planning Orders are pushed through Orders are pulled through
factory based on production factory based on
plan/forecast customer/downstream demand
Batch size Large Small
Quality inspection Checking of samples by QC In-line inspection by workers
Inspectors
Inventory Buffer of work-in-progress Little or no work-in-progress
between each production stage between each production stage
Handoff of work-in-progress Materials after each stage Materials handed off directly
accumulate into work-in- from one production stage to
progress storage areas before the next
being retrieved by next
production stage
Production cycle time Total production cycle takes Total production cycle
significantly longer than shortens to approach time
actual time spent in processing spent actually in processing
the materials the materials
Table 2- Key Implication of Lean Manufacturing

Lean and Six sigma:

Both the Lean and the Six Sigma methodologies are used to achieve dramatic improvements in
cost, quality, and time by focusing on process performance. Whereas Six Sigma is focused on
reducing variation and improving process yield by following a problem-solving approach using
statistical tools, Lean is primarily concerned with eliminating waste and improving flow by
following the Lean principles and a defined approach to implement each of these principles.
 Figure 7- Model of Lean Production System

Six-Sigma is analytical technique that focuses on quality and reduction of defects while Lean is
a management system that focuses on delivering value to the end customer by continuously
improving value delivery processes. Six sigma is a measurement denoting near perfection,
representing six standard deviations or 3.4 defects per million opportunities; the ideal against
which actual performance is measured. Lean provides a robust framework that facilitates
improving efficiency and effectiveness by focusing on critical customer requirements.

Most companies have either a Lean or Six Sigma program in place. However, using either one of
them alone has limitations: Six Sigma will eliminate defects but it will not address the question
of how to optimize process flow; and the Lean principles exclude the advanced statistical tools
often required to achieve the process capabilities needed to be truly ‘lean’. Therefore, most
practitioners consider these two methods as complementing each other. 

The fusion of lean and six sigma is required because lean can’t bring a process under statistical
control and six sigma can’t dramatically improve process speed or reduce invested capital. Both
lean and six sigma methodology are essential to the rapid and sustainable cost-cutting. The
integration of lean and six sigma is one of the most effective methods for consistently
improving cost, speed & quality, with broad success in service as well as manufacturing
functions.

The integrated approach to process improvement (using Lean and Six Sigma) will include:

 Using value stream mapping to develop a pipeline of projects that lend themselves
either to applying Six Sigma or Lean tools.
 Teaching Lean principles first to increase momentum, introducing the Six Sigma process
later on to tackle the more advanced problems.
 Adjusting the content of the training to the needs of the specific organization – while
some manufacturing locations could benefit from implementing the Lean principles with
respect to housekeeping, others will have these basics already in place and will be ready for
advanced tools.

The following roadmap provides an example for how one could approach the integration of
Lean and Six Sigma into a comprehensive roadmap.

Figure 8-Integrating Lean and Six Sigma Roadmap

Total Productive Maintenance (TPM):

TPM assigns basic preventive maintenance work including inspection, cleaning, lubricating,
tightening and calibration to the production workers who operate the equipment. It clearly
assigns responsibility to workers to pro-actively identify, monitor and correct the causes of
problems leading to unnecessary machine downtime. By doing this, maintenance problems are
less likely to occur and therefore machine downtime can be reduced.

Preventive maintenance is a series of routines, procedures and steps that are taken in order to
try to identify and resolve potential problems before they happen. In lean manufacturing, there
is a strong emphasis on preventive maintenance which is essential for minimizing machine
downtime due to breakdowns and unavailability of spare parts.

5.3 Six Sigma Methodology- DMAIC:

The DMAIC project methodology has five phases:

Figure 9- Five Steps of DMAIC

 Define the system, the voice of the customer and their requirements, and the project
goals, specifically.
 Measure key aspects of the current process and collect relevant data; calculate the 'as-
is' Process Capability.
 Analyze the data to investigate and verify cause-and-effect relationships. Determine
what the relationships are, and attempt to ensure that all factors have been considered.
Seek out root cause of the defect under investigation.
 Improve or optimize the current process based upon data analysis using techniques such
as design of experiments, poka yoke or mistake proofing, and standard work to create a
new, future state process. Set up pilot runs to establish process capability.
 Control the future state process to ensure that any deviations from the target are
corrected before they result in defects. Implement control systems such as statistical
process control, production boards, visual workplaces, and continuously monitor the
process.

Some organizations add a Recognize step at the beginning, which is to recognize the right
problem to work on, thus yielding an RDMAIC methodology.

5.4 Lean Principles:

As mentioned in lean integration there are seven core lean integration principles vital for
deriving significant and sustainable business benefit. They are as below:

1. Focus on the customer and eliminate waste: Waste elimination should be viewed from
the customer perspective and all activities that do not add value to the customer needs
 to be looked at closely and eliminated or reduced. In an integration context, the
customer is often an internal sponsor or group within an organization that uses,
benefits from, or pays for, the integrated capabilities.
2. Continuously improve: A data driven cycle of hypothesis-validation-implementation
should be used to drive innovation and continuously improve the end-to-end process.
Adopting and institutionalizing lessons learned and sustaining integration knowledge
are related concepts that assist in the establishment of this principle.
3. Empower the team: Creating cross-functional teams and sharing commitments across
individuals empower the teams and individuals who have a clear understanding of their
roles and the needs of their customers. The team is also provided the support by senior
management to innovate and try new ideas without fear of failure.
4. Optimize the whole: Adopt a big-picture perspective of the end-to-end process and
optimize the whole to maximize the customer value. This may at times require
performing individual steps and activities that appear to be sub-optimal when viewed in
isolation, but aiding streamlining the end-to-end process.
5. Plan for change: Application of mass customization techniques like leveraging
automated tools, structured processes, and reusable and parameterized integration
elements leads to reduction is cost and time in both the build and run stages of the
integration life-cycle. Another key technique is a middleware services layer that
presents applications with enduring abstractions of data through standardized
interfaces allows the underlying data structures to change without necessarily
impacting the dependent applications.
6. Automate processes: Automation of tasks increases the ability to respond to large
integration projects as effectively as small changes. In its ultimate form, automation
eliminates integration dependencies from the critical implementation path of projects.
7. Build quality in Process excellence is emphasized and quality is built in rather than
inspected in. A key metric for this principle is First time through percentage which is a
measure of the number of times an end-to-end process is executed without having to
do any rework or repeat any of the steps.

5.5 Advantages of IL6S:

Unlike other methodologies which restrict themselves to a specific part of improvement of the
overall business system/performance, IL6S multiplies the additive value of its element. It is:

 Fast – Delivers substantive results literally in a matter of weeks.

 Efficient – Delivers exceptional reductions in cost with relatively low investment.
  Effective – Provides a mechanism to identify, leverage and replicate best practices in cost
reduction across the enterprise.
 Practical – Provides fact-based, analytical, straight-forward methods used to uncover the
root causes of high cost, get waste of processes and transform plan in actions.
 Game changing – Creates competitive advantage in terms of operational cost, customer
quality and enterprise speed.
 Builds capability – Whether simple project execution or enterprise transformation, lean
six sigma imparts capability to the organization in a blended array of methods, including
e-learning, classroom participation, experiential learning or ‘just in time’ (JIT) project
support training.
 Transformational – Resources at all levels are engaged and aligned toward common
goals and projects that support business strategy.
 Sustainable – Links process metrics with performance management; engaging process
owners; and empowering front-line resources by providing them with control
mechanism to sustain gains.
5.6 Waste
1) Over-production: Producing too much.
2) Transportation: Any unnecessary transportation of the product.
3) Rework: Any repair or rework.
4) Motion: Any motion of the worker that does not add value.
5) Inventory: Any more than the minimum to get the job done.
6) Waiting: Waiting for parts, waiting for information.
7) Processing: Over-processing, process variability.
8) Intellect: Any failure to fully utilize the time and talents of people.

5.7 Loss Management

Three steps or phases related to achieving ideal state of zero loss:

1) Loss Intelligence: Identification of all your losses and prioritize them. Tools used are Loss
tree, Loss map & 6W2H (six why two how).
2) Loss Eradication: Elimination of losses completely. Tools used are RCA (root cause
analysis), Working principles, 4M analysis (man, method, material, machine), 5 Why
analysis, FI (focused improvement) 12 steps.
3) Loss Prevention: Using the DMS (daily management system) to ensure gains are
maintained through the PDCA (plan, do, check and act) process.
5.8 Kaizen
Objective of kaizen is to improve safety, quality delivery, cost sustainability, morale and
innovation through 100% employee engagement and improvement ideas driven culture.

KAI = Change

ZEN = Good (for the better)

KAIZEN = Improvement

Kaizen is a combination of two Japanese words KAI (change) and ZEN (good). Kaizen is the
methodology to analyze and eliminate losses. Any change for good can be termed as kaizen.
Kaizen is a (relatively) low cost, simple, team based approach. Kaizen is any small improvement
great or small done in the current working procedure, equipment condition or any process
leading to the benefits of the person or the organization.

“Kaizen System” is intended to improve all work processes and ensure a continued focus on
getting the little things right by engaging “everybody, everyday” by bringing natural work teams
together to generate ideas against problems & improvement opportunities.

Front-line workers see many problems and opportunities for improvement that can be resolved
quickly simultaneously in many areas across the factory through a simple idea system that is
primarily managed by individuals and line/area teams on the factory floor.

5.9 One Point Lesson (OPL)

A one point lesson is a communication on a brief standard operating procedure or SOP, it is
used to communicate to operators and staff new or revised standards or work methods that are
simple and do not require a full SOP.

A one point lesson could be as simple as communicating a new running pressure for a certain
vessel, a 5s standard to be implemented in a work area, a new hand operated tool to perform a
certain task, or even the relocation of a piece of machinery.

One point lessons can be written by any person in the organization. It is best practice for
operators and team leaders to write a one point lesson and communicate this to their peers
and teams. All one point lessons should be filed in a central area which is easy to access by
most teams and employees.

In some cases, they are kept in folders, filling cabinets or a dedicated OPL station. Operating
team members should be encouraged to check these on a regular basis to inform themselves of
any new one point lessons. This is usually implemented a daily or weekly basis among operating
teams. Managers should be checking regularly that the OPLs are being written for new brief
procedures or plant changes and that they are being distributed and ready by all operating
team members.

5.10 Cost Structure of Company:

There are total 3 types of cost occurring in any organization.

1) EM-PM Cost:

Cost responsible for purchasing raw materials such as Edible materials & Packaging
materials which are necessary for production.

2) Distribution and Warehousing Cost:

Cost, which is responsible for transporting the finished goods and holding the FG, in
warehouse.

3) Conversion Cost:

Cost, which is responsible for transforming raw material into finished goods, can be divided
into five categories:

i. EM-PM Waste: It includes overweight, scrap raw material, scrap packaging

material, material usage variance.
ii. Variable Factory Cost: It includes electricity, steam and compressed air.
iii. Indirect: It includes spares, contractors, gloves, duster, paper, pen, chemicals and
travel.
iv. People Cost: It includes employee salary, transport, uniform, food and overtime.
v. Depreciation: It includes wear and tear cost of machines.
 TESTING OF THE EDIBLE MATERIAL

1. MOISTURE CONTENT

Moisture content is defined as the percentage of water in a chocolate products. Moisture in

some form and amount is found in almost every product and can have different effects on the
products.
Determination of the moisture content is important for-

 Legal and Labeling Requirements: There are legal limits to the maximum or minimum
amount of water that must be present in certain types of food.
 Economic: The cost of many foods depends on the amount of water they contain
Microbial Stability: The propensity of microorganisms to grow in foods depends on their
water content.
 Food Quality: The texture, taste, appearance and stability of foods depends on the
amount of water they contain.
 Food Processing Operations: A knowledge of the moisture content is often necessary to
predict the behavior of foods during processing, e.g. mixing, drying, flow through a pipe
or packaging
 Determination of food shelf life
 Establishing dry weight of food
 Determining yield

Methods to Measure Moisture Content

1.1 VACUUM OVEN

Vacuum drying is generally used for the drying of those

substances which are hygroscopic and heat sensitive and is
based on the principle of creating a vacuum to decrease the
pressure below the vapor pressure of the water.

Requirements-

Sample, Petri dish, spatula, desiccator, oven, tongs, weighing

balance

Procedure-
  Take a Petri dish & note down its weight.
 Take 2 gm. of sample in Petri dish.
 Put the dish in oven.
 Set the temperature 80 0C and 680mm Hg pressure for 4 hrs.
 Now put the dish in desiccators for 15-20 minutes.
 Weigh the dish and note down the weight.

Calculation-

Moisture content%= W2 - W3X 100

Weight of dry empty Petri dish = W1

Weight of sample with Petri dish before drying = W2

Weight of the sample=W= W2 - W1

Weight of sample with dish after drying = W3

Scope-

It is used for cocoa liquor and cocoa powder

1.2 HOT AIR OVEN

Hot air ovens are electrical devices which use dry heat to sterilize. Generally, they can be

operated from 50 to 300 °C, using 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.

Requirements-

Sample, Petri dish, spatula, desiccator, oven, tongs, weighing

balance

Procedure-
  Take a Petri dish & note down its weight.
 Take 2 gm. of sample in Petri dish.
 Put the dish in oven at temperature 1050C for 4 hrs.
 Now put the dish in desiccators for 15-20 minutes.
 Weigh the dish and note down the weight.
Calculation-

Moisture content%= W2 - W3X 100

Weight of dry empty Petri dish = W1

Weight of sample with Petri dish before drying = W2

Weight of the sample=W= W2 - W1

Weight of sample with dish after drying = W3

Scope-

It is done for all edible material moisture analysis.

2. TOTAL ASH

The ash content is a measure of the total amount of minerals present within a food, whereas
the mineral content is a measure of the amount of specific inorganic components present
within a food, such as Ca, Na, K and Cl.

Determination of the ash and mineral content of foods is important for a number of reasons:

 Nutritional labeling. The concentration and type of minerals present must often be

stipulated on the label of a food.
 Quality. The quality of many foods depends on the concentration and type of minerals
they contain, including their taste, appearance, texture and stability.
 Microbiological stability. High mineral contents are sometimes used to retard the
growth of certain microorganisms.
 Nutrition. Some minerals are essential to a healthy diet (e.g., calcium, phosphorous,
potassium and sodium) whereas others can be toxic (e.g., lead, mercury, cadmium and
aluminum).
  Processing. It is often important to know the mineral content
of foods during processing because this affects the
physicochemical properties of foods.

Requirements-

Sample, Petri dish, spatula, desiccator, tongs, weighing

balance, muffle furnace

Procedure-

 Take a crucible & note down its weight.

 Take 2 gm. of sample in it.
 Set the muffle furnace at temperature 5500C and keep the crucible in it for 4 hrs.
 Now put the crucible in desiccators for 15-20 minutes.
 Weigh the dish and note down the weight.
Calculation:

Total ash = (W 3 - W1) × 100

W2

W3 = weight of crucible and total ash (final weight)

W1= weight of empty crucible

W2= weight of the sample in g

Scope-

It is done for milk powders, nuts and cocoa powder.

MALVERN PARTICLE SIZE ANALYZER 3000

It is used to determine the particle size of chocolates.This instrument is based on the technique
of laser diffraction exploit in order to determine particle size. A typical system consists of a
laser, to provide a source of coherent, intense light of fixed wavelength; a series of detectors to
measure the light pattern produced over a wide range of angles; and some kind of sample
presentation system to ensure that material under test passes through the laser beam as a
homogeneous stream of particles in a known, reproducible state of dispersion. The dynamic
range of the measurement is directly related to the angular range of the scattering
measurement, with modern instruments making measurements from around 0.02 degrees
through to beyond 140 degrees . The wavelength of light used for the measurements is also
important, with smaller wavelengths (e.g. blue light sources) providing improved sensitivity to
sub-micron particles.

WORKING OF MASTERSIZER 3000

The Mastersizer has been designed to measure the size of particles or, more specifically, the
distribution of different sizes within a sample. Scientists have for centuries tried to predict the
way particles scatter and absorb light. There are many theories and models that the modern
particle size analyst can use. One of the simplest theories used is the Fraunhofer model. This
model can predict the scattering pattern that is created when a solid, opaque disc of a known
size is passed through a laser beam.This model is satisfactory for some particles but it does not
describe the scattering exactly. Very few particles are disc shaped and most particles are
transparent.

The accepted theory which accurately predicts the light scattering behavior of all
materials under all conditions is known as the Mie theory. Mie theory was developed to predict
the way light is scattered by spherical particles and deals with the way light passes through, or
is adsorbed by, the particle. This theory is more accurate, but it does assume the user knows
some specific information about the particle, such as its refractive index and its absorption.

The key point about these theories is that if the size of the particle and other details about its
structure is known, the way it will scatter light can be predicted accurately. Each size of particle
will have its own characteristic scattering pattern, like a finger print, that is unlike any other size
of particle.

The MASTERSIZER works backward from the above theories by using the optical bench to
capture the actual scattering pattern from a field of particles. Then using the theories it
calculate the size of particles that created the pattern.

There are three distinct procedures in measuring a sample on the mastersizer:

1. The sample is prepared and dispersed to the concentration and then delivered to the
optical bench. This is the purpose of the sample dispersion units. Sample preparation is
the most important stage of making a measurement. Remember that, if the sample is
poorly prepared (unrepresentative or badly dispersed) then the basic data will be
incorrect; no amount of analysis of this data will give a correct answer.

2. The capturing of the scattering pattern from the prepared sample – this is known as the
“measurement”. This is the function of the optical bench.

The detector array within the optical bench is made up of many individual detectors.
Each detector collects the light scattering from a particular range of angles. Each bar in
 the histogram represents the light scattering from one of the detector elements (known
as a channel)

The detector array takes a “snapshot” of the scattering pattern. Obviously this snapshot
only captures the scattering pattern from the particles that are passing through the
analyser beam at that particular beam. Taking only one snapshot may not give a
representative reading of the scattering pattern. To overcome this, theMastersizer
takes many snapshots (known as snaps) and the averages the result. Typically over 2000
snaps are made for each measurement, with each snap taking 1ms.

3. Once the measurement is complete, the raw data from it is analysed by the Malvern
software using one of the theories mentioned above. Once the data has been analysed
the information can be displayed in various ways.

Note the following points regarding the measured data and the analysis.
 Analysing the measurement data does not permanently alter the data. The
measurement data can be re-analysed using different methods over and over
again.
 The software makes a measurement and then analyses the data automatically.

STEPS FOR WORKING OF MASTERSIZER

A. SAMPLE PREPARATION
 Testing with MCT OIL

1.Weigh 0.160 gram sample and transfer the sample to test tube containing 15 ml MCT oil
2. Sonicate the sample for 2 minutes over Sonicator to homogenise the sample

B. PROCEDURE
1. Switch on the instrument and the main switch.

2. Switch on the computer CPU.

3. Then switch on the mastersizer 3000 optical bench.

4. Double click on the Malverne 3000 icon to start the software.

5. Click on the configure accessories on the menu bar.

6. Confirm that the drain valve is closed.

7. Fill the sample port with MCT 60.

8. Increase the stirrer speed to 3500 rpm.

9. Fill the tank till the dispersant is sensed by the liquid sensor.

10. Set the stirrer rpm to 2150 for measurements.

11. Check the Initialise inurement and then check measure

background.

12. Sonicate the sample in the sonicator for 2 minutes.

13. After adding sample wait for 2 minutes.

 14. Select measure sample to see the trend.

15. After stabilization in the obscuration range click on measure sample.

16. Then results will be automatically saved.

17. Click on the record tab to see the results.

18. Drain the sample dispersant and then clean the sample Dispersion unit .

3. FOSS NIR
Near-infrared spectroscopy is based on
molecular overtone and combination
vibrations. Such transitions
are forbidden by the selection
rules of quantum mechanics. As a
result, the molar absorptivity in the near-IR region is typically quite small. One advantage is that
NIR can typically penetrate much farther into a sample than mid infrared radiation. Near-
infrared spectroscopy is, therefore, not a particularly sensitive technique, but it can be very
useful in probing bulk material with little or no sample preparation.

The molecular overtone and combination bands seen in the near-IR are typically very broad,
leading to complex spectra; it can be difficult to assign specific features to specific chemical
components. Multivariate (multiple variables) calibration techniques (e.g., principal
components analysis, partial least squares, or artificial neural networks) are often employed to
extract the desired chemical information. Careful development of a set of calibration samples
and application of multiv

4. HAAKE VISCOMETER
Using a rotational viscometer, the viscosity is calculated from the measured torque and
rotational speed as well as the dimensions of the measuring geometry. If the measuring
geometry fulfils certain requirements (e.g. small gap), which is the case for coaxial cylinder,
plate/plate and cone/plate measuring geometries (DIN 53018, DIN 53019...), the absolute value
of the viscosity can be calculated. If the dimensions of the measuring geometry are not well
defined, only a relative value for the viscosity can be determined. In this case, the measured
viscosity value not only depends on the ambient conditions, but also on the test method, i.e.
the measuring geometry

ariate calibration techniques is essential for near-infrared analytical methods.

TEMPERING
Tempering is the property of the liquid chocolate to solidify in the correct crystalline form to
give the solid chocolate its characteristic gloss and structure. A tempered chocolate is one
which contains the correct quantity of solid cocoa butter, having the desired crystal form in
proportion to the liquid cocoa butter.

Post-conching, the liquid chocolate is stored in jacketed storage tanks at a desired temperature
(typically ~ 45 ºC -50 ºC). The liquid chocolate passes through a Temperor, which is a heat
exchanger that cools the chocolate to around 29±0.5 °C. Then, re-heating it to around 31 °C to
convert the cocoa butter to the most stable form. Proper tempering ensures problems related
todemoulding and fat bloom are minimized.
 Fig: Tempermeter
• This newly developed Tempermeter allows even easier and more comfortable
measuring of the degree of chocolate temper.

• Printer, measuring probe, thermoelectric cooling system and a touch panel are all built
in.

• A single phase electrical connection is all that is required. This equipment is fitted with
an Ethernet and USB interface

• Itis used to measure the presence of various types of the crystal forms IV, V in semi-
molten cocoa butterin the preparation of well tempered chocolate.

It works by measuring “ the temperature of a standard weight of chocolate as it crystallizes

when cooled in a controlled way”.

 What is tempered chocolate?

 Project done for setting the flow rate of different SKU’S in temperor unit to
get the desirable tempering index
Tempering index range : 4 to 6, Slope : -0.2 to 0.2

CDM 25.3g

1W 18.20c 10.00c 14.10c 18.40c 17.60c 18.20c

13.00c 13.20c 14.00c 13.20c 14.00c 13.60c

1C 29.40c 29.30c 29.20c 29.20c 29.00c 29.30c

29.30c 29.50c 29.40c 29.50c 29.10c 29.50c

2W 31.30c 30.60c 31.20c 31.50c 31.90c 31.80c

31.30c 30.60c 31.30c 31.70c 32.00c 31.90c
2C 31.00c 30.90c 31.00c 31.10c 31.00c 31.10c
31.30c 31.50c 31.60c 31.40c 31.40c 31.50c

EW 32.00c 32.00c 32.00c 32.00c 32.00c 32.00c

32.00c 32.00c 32.00c 32.00c 32.00c 32.00c

Tempering 4.0 4.3 5.2 5.9 5.5 5.0

Index

Slope 0.2 0.1 0.0 -0.1 0.2 0.0

CDM 52 g

1W 17.80c 15.40c 18.20c 17.50c 16.40c 14.10c

14.00c 14.00c 13.20c 15.40c 14.20c 14.00c

1C 29.40c 29.30c 29.00c 28.90c 29.10c 29.20c

29.50c 29.50c 29.20c 29.00c 29.40c 29.50c

2W 31.80c 32.00c 31.60c 31.90c 31.80c 33.00c

32.00c 32.00c 31.90c 32.00c 31.90c 33.00c
2C 31.10c 30.90c 30.70c 30.90c 30.70c 31.10c
31.50c 31.40c 31.30c 31.20c 31.50c 31.50c

EW 32.00c 32.00c 32.00c 32.00c 32.00c 32.00c

32.00c 32.00c 32.00c 32.00c 32.00c 32.00c

Tempering 4.6 5.4 5.7 4.2 6.0 4.0

Index

Slope 0.0 0.1 0.2 -0.1 0.1 -0.2

Silk 60g

1W 15.40c 18.50c 16.40c 16.20c 15.30c 14.10c

12.00c 13.00c 13.00c 14.40c 14.00c 14.00c

1C 28.60c 28.40c 28.50c 28.40c 28.50c 28.30c

28.50c 28.50c 28.50c 28.50c 28.50c 28.40c

2W 31.50c 32.00c 31.70c 31.60c 32.00c 31.90c

31.50c 32.00c 31.60c 31.60c 32.00c 32.00c
2C 30.50c 30.80c 30.70c 30.50c 30.70c 30.90c
31.50c 31.00c 30.60c 30.60c 31.00c 30.70c

EW 32.00c 32.00c 32.00c 32.00c 32.00c 32.00c

32.00c 32.00c 32.00c 32.00c 32.00c 32.00c

Tempering 4.1 5.9 5.3 4.0 4.6 4.4

Index

Slope 0.0 -0.2 -0.1 0.2 0.0 0.1

Silk F&N 137 g

1W 17.40c 15.50c 18.40c 17.20c 18.60c 16.10c

13.00c 16.00c 15.00c 16.40c 17.00c 13.90c

1C 28.20c 28.10c 28.30c 28.10c 28.20c 28.40c

28.50c 28.20c 28.40c 28.20c 28.40c 28.50c

2W 31.20c 32.20c 31.70c 31.90c 31.70c 31.80c

31.50c 32.00c 31.90c 32.00c 31.80c 31.80c
2C 30.90c 30.40c 30.20c 30.90c 31.10c 31.20c
31.50c 30.50c 30.30c 31.20c 31.30c 31.30c

EW 32.00c 32.00c 32.00c 32.00c 32.00c 32.00c

32.00c 32.00c 32.00c 32.00c 32.00c 32.00c

Tempering 4.9 4.1 5.0 5.4 5.2 4.7

Index

Slope 0.2 -0.1 -0.2 0.1 -0.2 0.0

Silk 150g

1W 18.40c 16.50c 18.10c 17.20c 16.50c 17.10c

14.40c 15.00c 16.00c 14.80c 15.00c 15.00c

1C 28.40c 28.30c 28.10c 28.00c 28.60c 28.60c

28.50c 28.40c 28.50c 28.10c 28.50c 28.50c

2W 31.90c 31.80c 31.60c 31.70c 32.00c 32.00c

32.00c 31.90c 32.00c 31.90c 32.00c 31.80c
2C 30.70c 30.80c 30.70c 31.10c 30.70c 30.80c
31.20c 30.50c 30.80c 31.40c 31.00c 31.00c

EW 32.00c 32.00c 32.00c 32.00c 32.00c 32.00c

32.00c 32.00c 32.00c 32.00c 32.00c 32.00c

Tempering 4.6 5.4 5.1 5.8 4.4 5.1

Index

Slope 0.2 -0.1 0.1 0.0 0.2 0.1

CDM 36g

1W 16.80c 17.40c 15.20c 18.80c 16.40c 15.10c

14.00c 13.00c 12.00c 13.00c 14.20c 13.00c

1C 29.20c 29.10c 29.3 29.50c 29.10c 29.00c

29.50c 29.20c 29.50c 29.30c 29.40c 29.1v

2W 31.90c 31.70c 31.40c 31.80c 31.80c 32.00c

32.00c 31.80c 31.40c 31.90c 31.90c 32.00c
2C 31.30c 31.10c 30.60c 30.60c 30.70c 31.00c
31.50c 31.20c 31.10c 31.10c 31.50c 31.10c

EW 32.0 32.00c 32.00c 32.00c 32.00c 32.00c

32.0 32.00c 32.00c 32.00c 32.00c 32.00c

Tempering 5.9 5.2 4.1 5.3 6.0 4.5

Index

Slope 0.1 0.0 -0.2 0.1 -0.1 0.0

Silk RA 55g

1W 17.40c 16.40c 15.90c 16.50c 17.40c 16.40c

16.10c 13.00c 15.40c 15.80c 16.40c 15.00c

1C 28.00c 28.20c 28.10c 28.60c 28.60c 28.50c

28.20c 28.40c 28.40c 28.50c 28.70c 28.50c

2W 30.90c 31.90c 32.00c 32.00c 31.50c 31.70c

 30.50c 33.00c 32.00c 31.90c 31.50c 31.60c

2C 30.90c 30.10c 30.70c 30.70c 30.50c 30.70c

31.20c 30.50c 31.00c 31.00c 30.70c 30.80c

EW 32.00c 32.00c 32.00c 32.00c 32.00c 32.00c

32.00c 32.00c 32.00c 32.00c 32.00c 32.00c

Tempering 5.2 5.9 4.2 5.5 5.8 5.3

Index

Slope 0.2 -0.1 0.2 0.0 -0.1 -0.2

Silk RA 137g

1W 16.40c 15.70c 15.40c 16.80c 17.40c 16.20c

15.10c 15.00c 15.00c 15.00c 14.40c 15.00c

1C 28.10c 28.20c 28.30c 28.00c 28.00c 28.20c

28.20c 28.40c 28.40c 28.20c 28.20c 28.50c

2W 30.40c 31.90c 30.90c 31.00c 31.80c 31.70c

30.50c 33.00c 31.00c 31.00c 32.00c 31.80c
 2C 30.40c 30.10c 29.90c 29.90c 30.90c 30.60c
31.50c 30.50c 30.00c 30.00c 31.00c 30.80c

EW 32.00c 32.00c 32.00c 32.00c 32.00c 32.00c

32.00c 32.00c 32.00c 32.00c 32.00c 32.00c

Tempering 4.2 4.4 4.9 5.2 4.8 5.6

Index

Slope -0.1 0.1 0.2 0.0 -0.2 0.0

5 S OF THE QUALITY ASSURANCE LAB (UNIT -2)

Japanese English Typical Example

SEIRI Sort Separate the necessary and unnecessary

SEITON Set in Order Fix everything to order, minimize the

movement, visualize the abnormal

SEISO Shine Operator take the responsibility of own

 workplace; Eliminate sources of contamination,
reduce the cleaning time; 5 minutes 5S

SEIKETSU Standardize Visualize all standard and be

understood/improved by all operators

SHITSUKE Sustain PDCA: 1S-4S

BENEFITS OF 5S-

 Zero Defects Bring Higher Quality

 Zero Waste Brings Lower Costs
 Zero Delays Bring Reliable Deliveries
 Zero Injuries Promote Safety
 Zero Breakdowns Bring Better Maintenance
 Zero Complaints Brings Greater Confidence and Trust

1S-SORT

Take out unnecessary items and throw them away

Sorted the chemicals according to their nature and store them accordingly.

How does it help?

 Clears the clutter

 Creates more space
 Action on housekeeping problems

2S-SET IN ORDER

A PLACE FOR EVERYTHING AND EVERYTHING IN ITS PLACE

Assigned a name and location to everything and Reinforced names and location by markings
(e.g. labelling, outlining, placement marking, etc.)
How does it help?
Create neatness for

 Efficiency
 Quality
 Safety

3S-SHINE

CLEAN EVERYTHING TO CREATE AN IMPECCABLE PLACE AND INSPECT FOR DEFECTS

Conducted thorough cleaning of everything under a 3-step approach

 Step 1: Macro cleaning involving major housecleaning of spaces, furniture and

machinery
 Step 2: Individual cleaning of equipment and locations by allocating responsibility to
areas/zones
 Step 3: Micro cleaning of tools, parts, equipment interiors, etc.
How does it help?

 Creates an impeccable place

 Makes defects and problems visible
 Improvements through action on problems

4S-STANDARDIZE

MAINTAIN A HIGH LEVEL OF HOUSEKEEPING ALL THE TIME

 Establish and maintain clear standards

 Used symbols such as corrosive, flammable, etc to mark the chemical shelves.
 Marked all the instruments boundary

How does it help?

 Maintains a good workplace as a continuous activity
 Allows early detection of abnormalities for early action
 Makes the workplace look pleasant

5S-SUSTAIN

DEVELOP GOOD HOUSEKEEPING HABITS THROUGH LOT OF PRACTICE

 Provide clear communication and training to all personnel

 Involve everyone. Assign clear responsibilities to all
How does it help?

 Creates self-discipline for 5S

 Right habit formation
 Standardized behavior for achievement of results.