A

Training Report
Of
Summer Training Project at

On
Analysis
In the Partial Fulfillment of
Bachelor of Technology
Department of Food Technology

School of Vocational Studies and Applied Sciences

Gautam Buddha University
2018-19

Under the guidance of: Submitted by:

Ms. Ruchita Pal & Vanshika Srivastava (17/IFT/017)
Mr. Dinesh Rohilla B. Tech in Food Processing and
Technology
2nd year IVth Semester

1
 ACKNOWLEDGEMENT

I would like to extend a warm thanks to all the people who had been associated with me in
some way or the other and helped me to avail this opportunity for this experience.

I would like to give thanks to the HR, MR. AJAY CHOUBEY and MR. ATUL, for giving me the
opportunity for pursuing my training session at “BIKANERVALA FOODS PRIVATE LIMITED”

I sincerely thank my training guides, MS. RUCHITA PAL and MR. DINESH ROHILLA, for
providing me with the valuable insights on the training, correcting me and guiding me
throughout the training session.

I am particularly grateful to MR UPENDRA SINGH for their constant support and guidance.

I would like to thank all those people who directly or indirectly helped me throughout my
training.

VANSHIKA SRIVASTAVA
B. Tech Food processing and technology
2nd year IVth Semester
(GAUTAM BUDDHA UNIVERSITY
GREATER NOIDA)

2
 Company Profile

History
Bikanervala is a manufacturer of Indian sweets and snacks (namkeen). It was started by
Shyam Sunder Aggarwal who came to Delhi with his brother all the way from Bikaner.
The passion for food and its preparation has run in the Bikanervala family for generations,
and the brothers decided to take their training and traditions all the way from Bikaner,
Rajasthan to Delhi. In 1950, they set up their first little shop in Chandni Chowk and went on
to make their mark in traditional sweets.

Franchise
Bikanervala and its affiliate Bikano have a network of franchise. In 2015, the owner was
found to be using predatory practices with its franchise, taking the money for franchise
investment and then taking over the franchise based on sales. Since then company has
indicated shift to company owned outlets from franchise.
To transform the traditional heritage of Indian taste to Modernised India’s processed food,
Bikanervala begun the revolution as “Bikano” and started manufacturing Indian food with
International standards and expectation.
They produce internationally acclaimed packaged sweets, namkeens, snacks, papads, and sharbats.
Bikano has successfully transformed Traditional technique into Modern Technology.
Today, their products are being patronized by Multinational Companies, Modern Hyper
Markets, CSD Network, Indian Railways and Airlines in addition to numerous retail stores.
Their packed products with standard specifications & long shelf life are available in major
World markets & continents like Asia, Australasia, United States, Europe, Africa & Middle-
east.

3
 Products
The Bikano plant of Greater Noida mainly manufactures Namkeen of more than 40 variants
such as:

1. Aloo bhujia 2. Bikaneri bhujia

3. Tasty Peanuts 3. Moong Dal

And many more…

4
The two main departments at this plant were:
a) Quality and Analysis department
b) Production department

Quality and Analysis department

The whole plant of Bikano runs entirely on oil, which is why it is absolutely important that the oils
being used are of the best possible quality.

Bikano mainly uses three types of oils: -

a) Palmolein oil
b) Rice bran oil
c) Cottonseed oil

Out of these three oils only two oils are used at a time.

During summers, palmolein and rice bran oil and during winters, cottonseed and rice bran oil.

Palmolein oil is not used in winters because of its high freezing point of 14°C. Which is why in winters
cottonseed oil is used which has a freezing point of 6°C along with rice bran oil which has a freezing
point of 6°C as well. This helps the namkeen to not freeze in winters and still be consumable.

Since the entire industry functions on oil, it is necessary that the oil be in the best possible condition.
To check the condition of oil we test samples of oils for

• Free fatty acids,

• Oxidation value,
• Peroxidase value
• Iodine value.

Another thing that must be tested are the raw materials as well as the finished goods. Each product
whether raw or finished must have some factors in a particular range for that product to be
accepted. For raw and finished products, we test the

• Salt percentage
• Acidity percentage
• Moisture content

These tests are done daily as and when the raw materials are received and the finished goods are
packed.

The important raw materials at Bikano are

• Potato
• Peanuts
• Dry fruits
• Peas
• Chana
• Various dals (chana, moong)
• Whole spices

5
The finished goods include all the namkeens as well as their seasonings.

Tests conducted for oils:

Determination of free fatty acids (FFA) in oil
Take 50 ml ethanol
OR
Take 45 ml Isopropyl Alcohol and 5 ml distilled water in a conical flask.

Neutralize this by using 3-4 drops of phenolphthalein indicator and titrate with 0.1N NaOH.

Pink colour appears.

Tare this solution on weighing balance.

Take 20g of oil sample.

Boil the solution if Ethanol

OR
Heat the solution if IPA.

Titrate the solution with 0.1N NaOH by using 3-4 drops of phenolphthalein indicator.

Titrate it till light pink colour appears.

2.82 × 𝑇
𝐹𝐹𝐴 𝑜𝑓 𝑜𝑖𝑙 =
𝑊

Where,

T: Titer value
W: Weight of sample

6
 Determination of oxidation value of oil
Switch on spectrophotometer and keep it warm for 30 minutes.

Take 0.5g oil sample in a 25 ml volumetric flask.

Make up 25 ml by using iso-octane and shake well (this is sample A).

Fill iso-octane in first cuvette and place it in spectrophotometer’s cell and adjust the
wavelength at 350nm and set the transmittance at 0.

In second cuvette take oil sample solution (A) and place it in cell and not the absorbance as
(Ab).

Take 1 ml anisidine solution in a culture tube and add 5 ml iso-octane. Start stop watch.

In another tube take 1 ml anisidine solution and 5 ml solution A (this is sample B) and note
the time.

At the end of the 10 minutes in third cuvette take a sample from first culture tube and place
it in cell and adjust transmittance at 0.

From second culture tube take a sample B in fourth cuvette and place it in cell and note the
absorbance as (As).

[1.2 × (𝐴𝑠 − 𝐴𝑏)] × 25

𝑂𝑥𝑖𝑑𝑎𝑡𝑖𝑜𝑛 𝑣𝑎𝑙𝑢𝑒 =
𝑊

Where,
As: Absorbance of sample
Ab: Absorbance of blank
W: Weight of oil sample

7
 Determination of peroxide value of oil
Take 5g oil sample in stoppered iodine flask.

Add 30 ml of solvent mixture.

(Chloroform:Acetic Acid::2:3)

Add 0.5 ml freshly prepared saturated KI.

Hold for 1 minute in dark.

Add 30 ml distilled water and mix gently.

Add 0.5 ml freshly prepared starch indicator (1%).

Titrate with 0.1 N Sodium Thiosulphate.

Titrate till milky colour appears.

(𝑆 − 𝐵) × 𝑁 × 1000
𝑃𝑒𝑟𝑜𝑥𝑖𝑑𝑎𝑠𝑒 𝑉𝑎𝑙𝑢𝑒 =
𝑊

Where,
S: Titer value of sample
B: Titer value of blank
N: Normality of Sodium Thiosulphate
W: Weight of sample

8
 Determination of iodine value of oil

Weigh 0.5 g sample in a stoppered iodine flask.

Add 10 ml Carbon Tetrachloride.

Add 25 ml Wiz Solution.

Store in dark for 30 minutes.

Add 15 ml freshly prepared 10% KI solution.

Add 50 ml distilled water and mix it well.

Titrate the solution with 0.1 N Sodium Thiosulphate (using 4-5 drops of freshly prepared 1%
starch solution).

Titrate it till light pink and milk colour appears.

Conduct the same with blank.

(𝐵 − 𝑆) × 𝑁 × 12.69
𝐼𝑜𝑑𝑖𝑛𝑒 𝑣𝑎𝑙𝑢𝑒 =
𝑊

Where,
B: Titer value with blank
S: Titer value with sample
N: Normality of Sodium Thiosulphate
W: Weight of sample

Preparation of Wiz solution

Dissolve 8g Iodine Trichloride with 200 ml Glacial Acetic Acid and mix with 9g Iodine
dissolved in 400 ml Glacial Acetic Acid.

9
Tests conducted for raw materials and finished goods:

Determination of salt percentage

Weigh 2g of crushed sample or 0.5g of spices/seasoning.

Add 200 ml distilled water.

Shake for 5 minutes (on magnetic stirrer).

Filter using filter paper.

Take 10 ml of filtrate.

Add 10 ml distilled water.

Titrate the solution with 0.1 N Silver Nitrate solution (using 4-5 drops of Potassium
Chromate 5% solution)

Record the titer value at end point when “brick red” colour appears

𝑇 × 𝑁 × 58.45
𝑆𝑎𝑙𝑡 % =
𝑊

Where,

T: Titer value
N: Normality of Silver Nitrate solution
W: Weight of sample

10
 Determination of acidity percentage
Weigh 2g of crushed sample or 0.5g of spices/seasoning.

Add 200 ml distilled water.

Shake for 5 minutes (on magnetic stirrer).

Filter using filter paper.

Take 10 ml of filtrate.

Add 10 ml distilled water.

Titrate the solution with 0.1 N Sodium Hydroxide solution (using 4-5 drops of
phenolphthalein indicator).

Record the titer value at end point when “pink” colour appears.

𝑇 × 𝑁 × 64.03
𝐴𝑐𝑖𝑑𝑖𝑡𝑦 % (𝑎𝑠 𝑐𝑖𝑡𝑟𝑖𝑐 𝑎𝑐𝑖𝑑) =
𝑊

𝑇 × 𝑁 × 67.045
𝐴𝑐𝑖𝑑𝑖𝑡𝑦 % (𝑎𝑠 𝑚𝑎𝑙𝑖𝑐 𝑎𝑐𝑖𝑑) =
𝑊

𝑇 × 𝑁 × 74.00
𝐴𝑐𝑖𝑑𝑖𝑡𝑦 % (𝑎𝑠 𝑡𝑎𝑟𝑡𝑎𝑟𝑖𝑐 𝑎𝑐𝑖𝑑) =
𝑊

Where,
T: Titer value
W: Weight of sample
N: Normality of Sodium Hydroxide solution

11
Determination of moisture by halogen moisture meter
Check the power supply.

Switch ‘ON’ power supply.

Switch on moisture meter.

Set the required temperature (105°C).

Place the sample for drying in moisture meter.

Wait for required temperature (40°C) and press start button.

Wait for drying of sample till the temperature falls.

Note down the reading which is displayed in %.

After drying of sample switch off the ‘main’.

Switch off the power supply.

12
 SENSORY

Another thing that was important in the lab was sensory.

Sensory is the procedure of testing of the finished goods by tasting.

At Bikano, each day only four finished namkeens from each of their three batches were
tested for the following factors:
1. Appearance
2. Taste
3. Texture

These factors were then marked accordingly like this:

Marks 0 1-2 3

Action to be taken Go Go but take action No go

13
 LAMINATE
The laminate is another important factor here in Bikano and therefore an equal attention is
given to this part too.
Laminate is the wrapper or the pouch in which the namkeen is packaged and dispatched
and that is what gives us the information about the variety of namkeens.
These are primarily in the form of rolls which are then attached to the ‘Vertical form fill
machine’ which discharges the right amount of product to be packed.
A few things that are checked at Bikano checked in a laminate are:

a) Dimension
b) Printing
c) Art work
d) Pin holes
e) GSM
f) Eye mark

Each factor is important in different ways.

a) Dimension:
The dimension i.e. The measure of length, breadth and width of ONE laminate in the whole
roll should be perfect in order to ensure correct sealing and cutting of packets.

b) Printing:
Printing of the laminate mainly refers to the printing of all the details required as per the
standards of the governing bodies. It is very important that the laminate consists of the
following details:
• The Name of Food
• List of Ingredients
• Nutritional information
• Declaration regarding Veg or Non veg
• Declaration regarding Food Additives-
• Name and complete address of the manufacturer
• Net quantity
• Lot/Code/Batch identification
• Date of manufacture or packing
• Best Before and ‘Use By’ Date
• Allergen warning

14
 c) Art work:
It is the printing done on the laminate which represents the product we get inside. It should
be as attractive as possible to catch the attention of the consumers.
The artwork includes printing the brand name, name of product (e.g. Aloo Bhujia), a visual
representation of the same product all in colours which might please the consumers.
Even in terms of colours, the laminate could have a darker or lighter shade which might not
be acceptable by the company.

d) Pin holes:
Pin holes are small pin-sized holes in packets or pouches caused due to various reasons
which include
• damage in the initial laminate itself
• damage during filling and sealing
• mishandling while packaging
These pinholes, if by any chance are found in a packet or pouch, the product is not allowed
to leave from the factory and is discarded immediately.

e) GSM:
GSM, in the pulp and paper and the fabric industries, are the areal density of a paper or
fabric product, that is, its mass per unit of area.
Expressed in grams per square meter (g/m2), paper density is also known as grammage. This
is the measure used in most parts of the world.
The unit is often used to measure density or thickness of paper.
In a way, measuring GSM helps us find out the strength of the laminate.

f) Eye mark:
The eye mark is a black patch at the end of one part of laminate in one roll. The function of
this eye mark to detect the end of one part of laminate in the vertical form fill machine.
When this machine detects this black eye mark, it gets the signal to start sealing one end of
the packet, the product is then discharged in the formed packet and the next eye mark tells
the machine to seal the top of the same packet. This competes the formation and sealing of
one packet of namkeen.

15
 MULTIHEAD WEIGHERS
A multihead weigher is a fast, accurate and reliable weighing machine, used in packing both
food and non-food products.
Multihead weigher is automatic weighing equipment to achieve high speed, accuracy and
stable performance.

Main components

Main Vibrator: Main vibrator is the vibrating source for the top cone, from top cone;
product will be distributed to linear vibrator pan.

Linear Vibrator: Linear vibrator is the vibrating source for the linear vibrator pan; product
will be distributed to intermediate hopper (feed hopper).

Intermediate (Feed) Hopper: Intermediate (feed) hopper receives products from linear
vibrator. It will discharge product to weigh hopper which is below it, when weigh hopper is
empty.

Weigh Hopper: Each weigh bucket is connecting to load cells and it will read weight of
product inside the weigher, and controller will use the weighted data to make combination.
Selected weigh hopper will discharge products to the collecting hopper or machine.

16
Working theory
The product is fed to main vibrator pan than it is distributed to feed hopper by linear
vibrator pan of each head. Each feed hopper will drop the product into weigh hopper as
soon as it becomes empty. The weigher computes the product weight in individual weigh
hopper and identifies which combination contains weight closest to target weight. The
Multihead weigher will open all the hopper of this combination and product falls to the
packaging machine. The working principle of Multihead weigher is as shown in chart.

After this, the feed is dispensed into the packets formed with the help of Vertical fill, form,
seal machine.

17
 VERTICAL FORM, FILL, SEAL MACHINE

One machine that we thoroughly understood was the ‘Vertical form, fill, seal machine.’

What is VFFS?
Vertical form, fill, seal machines are extremely flexible machines. Widely ranging products
can be packed efficiently and effectively, and can be attractively presented – from your daily
coffee to hand-crafted tortellini, from a selection of fresh vegetables to frozen shrimp. And
of course, insecticides, detergents and marbles are also packed in bags.

VFFS machines are suited to a broad range of products that can be divided into the following
four main groups:
• bulk goods, varying from nuts and cookies to bolts and screws;
• powders, such as ground coffee and dehydrated milk;
• grains or granulate, such as dals and namkeens;
• liquids: usually one-time (portion) packages such as ketchup, mayonnaise, salad dressing.

18
THE PROCESS
Bag Making
In theory, all vertical packaging machines work the same. A flat web of film, originating from
a large roll of film at the start of the machine, is shaped into a tube. This tube is closed at
the bottom: this is the bottom of the new bag. As soon as the product is dispensed into the
bag, the top side is also closed. The time and steps that are needed to make one bag are
collectively called a machine cycle.

Three seams
A bag produced in this manner theoretically has three seams. The longitudinal seam is the
seam that runs down the length of the bag: here the left and right side of the originally flat
film web come together. The bottom seam closes the bottom of the bag; the top seam
closes the top. Both of these are also referred to as the cross seams.

Sealing
The seams are closed by sealing. To do this, the packaging material is compressed and
heated briefly, and the sealing medium (usually polyethylene) melts. As soon as the sealing
medium has cooled off enough, the seams are stable. This occurs in milliseconds.

Bottom, top and cutting

The sealing unit, at the bottom of the forming tube, contains four sealing bars. The lower
two sealing jaws form the top seam of the bag that has just been filled. At the same time,
the upper two jaws closer to the forming tube form the bottom seam of the next bag. The
blade that cuts and separates both the bags is located between the two sets of sealing jaws.
The film material is compressed together and heated by the sealing jaws.

19
Forming tube and forming shoulder
Every packaging machine can form various different bag sizes, fill them and seal them. The
size and shape of the bag are determined by two important components: the forming tube
and the forming shoulder. The web of film is pulled over the forming shoulder, so that the
material around the forming tube is shaped from a flat film to a tube. The shoulder and tube
are collectively called the forming parts. Every bag width requires its own forming parts.

Overlap seam or fold-over seam

There are two types of longitudinal seams. In the overlap seam or lap seal one edge of the
web of film is placed over the other edge, so that the material overlaps. In this way, the
inside of the first edge is sealed to the outside of the other edge. With a fold-over seam or
fin seal, one edge of the web of film is folded over, so the inside of the one edge is sealed to
the inside of the other edge. The choice between these seams is determined by the
(structure of) packaging material

Dispensing
In order to ensure that the correct quantity of product is always packaged, a doser is
required. Depending on the product, the doser works on the basis of a filling weight per bag
(filling scale) or on the basis of a certain volume per bag (dispensing cup or auger dosing).
For liquids, a special pump is used that dispenses a certain amount of liquid for each
package. When packaging a certain number of product units per bag, a counting machine is
used.

20
 CONCLUSION
We have learnt from this training how an industry works. The various qualities or skills a
person has to have in order to handle machines as well as the manpower which is working for
the company, along with the processes involved in the production of namkeens.

We also got the basic idea of how a quality control and analysis lab works. We learnt, by
ourselves, to carry out all the above-mentioned experiments. Getting to train, mainly at the
lab has taught us its importance in any kind of food industry, and how the industry is directly
or indirectly, heavily based on it.

The experience we have had was truly amazing which can sure be useful to us in the future.

Thank you!

21