Internship Report Muhammad Arshad

INNOVATIVE BISCUTS Pvt.
Ltd
It is certified that no objectionable Submitted by: Muhammad Arshad

material is added in this report
Roll No. 2063
Submitted to: Dr. Tahir Nadeem
MR sign:
Session: 2011-2015
………………………………..
(BS Food Science and Technology)
M.ARSHAD
Internship report
5/23/2015
ACKNOWLEDGMENTS
In performing my internship, it's a successful one I had to take the help and guideline of some
respected persons. First of all I am grateful to Allah who gives me sound mind & sound health
to complete my internship at INNOVATIVE BISCUITS PVT. LTD. The completion of the
task gives me much Pleasure. Then I would like to thank Mr. Muhammad Shahzad (Factory
manager) for providing opportunity, good environment and facilities to complete this
internship. Besides, I would like to thank Mr. Khawar (Senior QA manger), Mr. Zameer
Haidr (QA manager), Mr. Nauman (Production manager) and Miss Shazia (Assistant
production manager) for sharing their knowledge and guiding in right directions.
In addition, I would like to thank to my classmate because of the availability from all of them
while discussing the topic, experience and ideas of this internship
Besides that, I would to appreciate my internship supervisor Miss Mariaum Riaz. She is the
person that in-charge in order to evaluate my assessment and performance related in working
industry. The supervision and support that she gave truly helped the progression and
smoothness of the internship program.
As the most important person, I also want to thank to Mr. Aamir Sheikh (Managing
Director) that giving me chance and opportunity to work in his organization in order to
complete my internship session.
Any omission is this brief acknowledgment does not mean lack of gratitude.
Thank you….
M.ARSHAD INTERNSHIP REPORT 1

INNIVATIVE BISCUITS (PVT) LTD.
INTRODUCTION AND HISTORY OF COMPANY

The company was formed in 2004 and today has expanded its operations massively. The
Innovative brand is now a strong consumers’ franchise, growing the fastest of any brand
nationwide, and spanning an extensive distribution network of 250 distributors and dealers in
Pakistan. Our highly committed and professional management team injects vigor and
excellence in every function of the business through strong experience in Marketing, Sales,
Production, R&D, HR, and Quality Assurance.
Innovative has consistently carried forward the banner of happiness for 11 years, so that the
brand name has now become synonymous with quality in biscuit and confectionary
manufacturing. With an emphasis on excellence in every area, we select the finest ingredients,
ensure hygienic conditions at every manufacturing stage and strive to deliver our promises to
the consumer. Quality and purity is set not only on our production floor but in our every
promise, principle and way of doing business. We have a strict policy of ensuring that no
artificial flavors and no artificial colors are added in any of our products. For all these
reasons, we enjoy the full trust and confidence of our consumers.
Innovative has consistently carried forward the banner of happiness for eleven years, so that
the brand name has now become synonymous with quality in biscuit and confectionery
manufacturing. With an emphasis on excellence in every area, we select the finest ingredients,
ensure hygienic conditions at every manufacturing stage and strive to deliver our promises to
the consumer. Quality and purity is set not only on our production floor but in our every
promise, principle and way of doing business. We have a strict policy of ensuring that no
artificial flavors and no artificial colors are added in any of our products. For all these
reasons, we enjoy the full trust and confidence of our consumers.
Within a short span of time the company rapidly grew and enhanced its plant and
manufacturing equipment and shifted temporarily to a land of 10 canals at 23 KM,
Sheikhupura Road, Lahore. Currently the company is spread over 65,000 square feet with a
Total Area of Plant and Factory of more than 67 Canals. The imported plant and equipment

are purchased form World’s Best Biscuits Manufacturing Company – United Biscuits (UK)
and the Oven Baking Unit is manufactured by Vicar Spooner (UK) the world’s best biscuit
machinery manufacturer. The company at present has the capacity to produce approximately
1.5 Tons biscuits per hour.
At Innovative, we also proudly uphold our corporate social responsibilities with a firm
commitment to protection of the environment and through productive contributions to
society.
Our passion for innovation has resulted in the finest brands now under its umbrella. Our range
of brands includes Biscuits, Wafers and Chocolates.
PRODUCTS
A variety of products is being produced at innovative under different brand names. Innovative
has three brand names for biscuit, wafer and chocolate.
1. Innovative
2. Cutees
3. Taste Maker
BISCUITS BRANDS WITH THEIR PRODUCTS
 Innovative:
 Jumboo
 Goodies
 Goodies with lemon flavor
 Digestive

 Peanut
 Zeera
 Choc N Chip
 Xtra
 Cutees:
 Topper
 Too Good
 Pea Nut
 Super Crunch
 Fighter
 Tracker
 Taste makers:
 Peanuts
 Tea Time
 Elaichi special
 Pista Maza
 Kingo
 Snoper
WAFERS BRAND WITH THEIR PRODUCTS
 Cutees:
• Plus Orange Wafers
• Plus Custard Wafers

• Plus Strawberry Wafers
• Plus Chocolate & Vanilla Wafers
 Tastemakers:
• Orange wafers
• Mango wafers
• Chocolate wafers
• Strawberry wafers
 Innovative:
• Trend Orange
• Trend Orange
• Trend Chocolate
• Wafers Creamy orange flavor
• Wafers Creamy Chocolate Flavor
• Wafers Creamy Strawberry
Flavor
• Wafers Creamy Vanilla
Flavor
 Frisky:
• Orange cream wafers

• Vanilla cream wafers
• Chocolate cream wafers
• Strawberry cream wafers

CHOCOLATE COATED WAFERS
BRAND WITH THEIR PRODUCTS
 Innovative
• Chocos
 Taste makers:
• Spark
• Chocolate wafers
• Orange wafers
• Mango wafers
• Strawberry wafers
 Cutees:
• Pick
• Tropik

EQUIPMENTS AND MACHINARY
USED IN INDUSTRY:
 WEIGHING BALANCE:
A weighing balance is an instrument capable of making
precise measurements of weight of objects. Weighing balance
is used to weigh different ingredients. There are two types of
weighing balance at plant. Least count of lab scale weighing
balance is 0.01g and mainly used to weigh the small fraction such
as salt, soda, biscuit weight etc. Second category balances are used
to weigh large quantities of materials in kilograms and have least
count of 0.01kg. All the weighing scales are electronic and have digital displays.
 WAFER MIXER:
Wafer mixer is used to mix the flour to make the batter for wafers. The water absorption
of flour may be important in mixing and this is strongly affected by the moisture and
protein contents. There are four lines of wafer and one line of chocolate coated wafers and
every line has its own mixer. There are two tanks of one mixer. One tank has an
arrangement of mixing mechanism upward the tank and second tank is used to hold the

batter for loading for further processing and uploading of batter is automatic according to
need of oven.
 WAFER OVEN:
Wafer oven is used for baking wafer sheets. Wafers are a very specialized type of biscuit
requiring special equipment for production. The sheets formed by baking between pairs of
heated metal plates, which are like large
steel book leaves hinged at one side, are
typically thin and usually bear intricate
surface patterns with deep relief derived
from the baking plates. Wafer sheets are
baked from a simple batter containing
little or no sugar. They are rather tasteless
and have a regular surface and a very
open cellular structure within. All the
oven have 65 plates and can operate on three speeds, 18, 20 and 22 respectively. Baking time
and temperature depends on speed of oven.
 COOLING TOWER:
Cooling tower is used to cool the wafer sheet. It
can hold 51 sheets at a time and directly drops
the sheets on creaming machine conveying belt
for the creaming of sheet. Cooling time also can
be adjusted according to requirement.

 CREAM SPREADING MACHINE:
Cream spreading machine is
used to spread. Wafer cream
spreading machines spread
an exact amount of fat cream
onto the wafer sheets and
automatically stack the
requested number of spread
sheets together with the
uncreamed top sheet into a
wafer block. The speed of
the two rollers and of the spreading belt can be adjusted independently of each other. The
uncreamed top sheet passes the spreading roller without contact due to cam-controlled
lowering of the spreading table. After spreading wafer blocks are formed out of three or four
wafer sheets with the spiral stacker. There the wafer sheets get maximum support and are
stacked. Exact block formation
guarantees a minimum of cutting
residue in the following cutting
process.
 WAFER CUTTING
MACHINE:
It is a steel wire cut machine to
cut the wafer sheets, which size is
adjustable through horizontal and vertical to finish cutting automatically. Sometime three
layer sheet in processed and sometime two sheets of three ply sheet are combined to process.
No of fingers produced from one sheet (three ply or six ply) depend on the space between
steel wire cut horizontally and vertically. A wafer cutting machine having eleven wires
horizontally and nineteen vertically can cut a sheet into 180 pieces because both sides are
wasted during wire cut

 MIXER FOR CREAM MIXING:
Cream mixer is used to mix the cream, sugar, flavor and color for proper application of cream
to the wafer sheets.
 SUGAR GRINDER:
Sugar grinder is used to grind the sugar in to desirable crystal size to sprinkle on the product
or to add in cream etc.

 MOULD:
Mould is used to give the shape to
biscuits. Mould is different for
different products.
 BISCUITS BAKING OVEN:

Biscuits baking oven is used to bake the biscuits. Length and width of all biscuit baking oven
are different and number of burners also vary. Mainly two type of ovens are being used to
biscuit baking.
1. Direct Oven: There are number of burners on the bottom and top of the steel belt
congaing the product for baking.
2. Indirect Oven: In this type only one large burner is present and heat in spread in oven
sections through moving air.
At innovative, ovens are 150-200 feet long. These are tunnel type ovens. Oven has three
zones and each zone gives specific characteristics to the biscuit. Each zone has its specific
temperature and air pressure.
1. First zone raises the biscuit.

Here the biscuit is allowed to
rise as much as possible.
2. Second zone bakes the biscuit.
3. Third zone gives color to the
biscuits.
Escape of gases and steam would result
in collapse of structure hence these are

passed on to different zones with gradual increase or decrease of temperature zones.
Some types of ovens also have five zones which give certain characters to the product.
 Following are the physical and chemical changes which occur in oven, when dough
piece is passed on to oven.
 Physical changes:
1. Formation of crust
2. Melting of fat
3. Gas expansion in dough piece due to Co2 expansion at higher temperatures
4. Water converted into steam
 Chemical changes:
1. Gas formation
2. Starch gelatinization
3. Protein changes
4. Caramelization of sugars
 BISCUITS STACKER:
Biscuits stacker is used to stack the biscuits. There are number of rows according to product
that are stacked into rows/lines for packaging.

 BISCUITS
Ingredients:
Toper:
• Water
• Wheat flour
• Hydrogenated vegetable oil
• Corn flour
• Fresh eggs
• Sugar
• Glucose syrup
• Skimmed milk powder
• Leavening agents {sodium bi carbonate, ammonium bicarbonate}
• Salt
• Artificial flavor
• Permitted food colors

Jumboo:
• Water
• Wheat flour
• Sugar
• Glucose
• Salt
• Raising agents (Sodium Bicarbonate E500 and Ammonium Bicarbonate E503)
• Soya Lecithin E322
• Calcium Carbonate E170
• Sodium Pyrophosphate E450
• Artificial Flavors
Choc ‘n’ chip:
• Water
• Wheat flour
• Vegetable oil
• Chocolate chips
• Raising agents (Sodium bicarbonate, Ammonium bicarbonate)
• Salt
• Permitted food color
Snoper:
• Water
• Wheat flour

• Vegetable oil
• Sugar
• Corn Flour
• Skimmed Milk Powder
• Fresh Eggs
• Salt
• Leavening Agents
• Acritical Flavor
• Permitted Food Color
Peanut:
• Water
• Wheat flour
• Hydrogenated Vegetable Oil
• Sugar
• Peanut Grits
• Skimmed Milk Powder
• Fresh Eggs
• Salt
• Leavening Agents (Ammonium Bicarbonate and Sodium Bicarbonate)
• Soya Lecithin
• Artificial Flavor

FUNCTIONS OF INGRIDIENTS
Biscuits provide almost double calories for regulation of body activities as compared to bread.
Biscuits are nutritious, convenient food with long shelf life, used as popular item of food.
Biscuits are good source to provide Ca, Carbohydrates, Fe, and Protein etc. Biscuit vary in
size, shape, texture, hardness, so biscuit making require great care, attention & keeping
quality level for producing a standard & better product
 FLOUR:
Flour is a very important ingredient which can impart unique appearance,

characteristic to the biscuit. Wheat flour is produced by milling the whole
wheat grain, which contain germ, bran & endosperm, but in biscuit
manufacturing onl y endosperm is used & is separated from germ & bran,
which is called as:white flour, Maida”
Gluten Formation:
When wheat flour is mixed with water and stirred or kneaded, the glutenin
and gliadin proteins not onl y bond with the water but also link and crosslink
with one another to eventuall y form sheets of a flexible, resilient film called
gluten. Protein content determines how much water a flour can absorb the
greater the amount.
Functions:
• Flour provides the structure in baked goods
• Acts as a binding agent
• Acts as an absorption agent
• Affects the taste
• Provides nutrition in final product
• Retain shape and volume after baking
• Major constituent of biscuit.

• It contains four proteins: Albumin, Globulin, Glutenin (controls
strength & structure of biscuit) & Gliadin (gives elasticit y to the
dough). Albumin & Globulin are soluble proteins. Glutenin & Gliadin
are insoluble proteins. Insoluble proteins combine with water to form
“Gluten”, & Gluten along with starch provides proper eating qualities.
 FAT:
• Fat provides nutrition, flavor & aids in development of physical
structure.
• Fat provides shortness and tenderness.
• Helps in flavor development
• Help in Emulsification
• Help in Aeration (creaming)
• Helps in heat transfer
• Improves the eating qualit y for prolong period
• Improves keeping qualit y of the product & increases its shelf life
 WATER:
Water is a basic ingredient in baking. It would be impossible to produce biscuits without

water in some form. It facilitates mixing of ingredients and other steps of processing. There
are certain functions of water which include:
• It makes possible the formation of gluten.

• It wets and swells the starch.
• It assists in controlling the temperature of dough a through adding cold or warm water
the temperature of the dough can be regulated.
• It dissolves salts, suspends and distributes non-flour ingredients uniformly.

 RAISING AGENTS:
• Sodium bicarbonate: (NaHCO3)
It is also known as baking soda. It releases carbon dioxide on being exposed to moisture and
acid. In baking, it is used for leavening or giving volume to breads, cookies, cakes, and some
candies. The volume and texture of the product depend largely on the amount added to the
batter or dough. Besides damaging the volume and texture, excess use of baking soda leaves
an after- taste and gives a light color to the finished product. Baking soda is often used in
chocolate cakes and cookies to raise the pH of cocoa.
• Ammonium bicarbonate:
It is used to a small extent as a leavening agent. Its use is primarily limited to a certain types
of cookies. The advantage of this type of leavening agent is that it decomposes into two gases
and does not leave a solid residue.
 SALT:
It is used for flavor and taste. It brings about the taste of other ingredients. Table salt should
have the following characteristics for use in the bakery items:
• It should be completely soluble in water.
• It should give a clear solution. Cloudy solution indicates presence of certain
impurities.
• It should be free from lumps.
• It should be as pure as possible.
• It should be free from a bitter or biting taste.
Functions:
• It is mainly added for taste
• Most effective concentration is around 1 – 1.5 % based on flour weight
• Used for flavor & flavor enhancing properties
• It should be completely soluble in water.

• It should be pure, free from lumps.
• Prevents the growth of undesirable bacteria in yeast raised dough
 SKIMMED MILK POWDER:

Milk contributes valuable nutrients to baked goods. It helps browning to occur, adds flavor
and improve texture. This is done to improve the quality of the dough and the volume of the
biscuits.
Dry milk used in the bakery products should be readily soluble.
When a fat is separated from the milk for cream & butter manufacture, a white fluid, rich in
lactose & protein remains. This is called Skimmed Milk & when this skimmed milk is dried
by evaporation or by spray-drying, it is called as “Skimmed Milk Powder”. The flavor of this
milk is very strong & is used in many ways during manufacturing of biscuits.
• SMP is a major dough ingredient, which is used to give flavor, texture & aids in
surface coloring.
• It has a binding effect on flour protein, creating a toughing effect.
• Improves flavor & is an important moisture retaining agent.
 EMULSIFIERS:
It is added to the dough during mixing to mix two immiscible things. Some of the more
common ones are monoglycrides, calcium steroyl lactylate, and sodium steroyl lactylate.
Some anti-staling ingredients also perform as dough conditioners or dough strengtheners.
Soya lecithin is being used as emulsifier in biscuits.
To stabilize mixtures of two immiscible liquids (normally oil & water), e.g., Soya Lecithin.
Soya lecithin is obtained from Soya origin. Being natural, it is exempted from controlled by
legislation. In any mixture of water & oil, lecithin exhibits a pronounced emulsifying action
by reducing the surface tension at the interfacial boundaries existing b/w oil & water phases.
This results in two distinct effects.
• Stabilizing oil in water emulsion
• Stabilizing water in oil emulsion

 SUGAR:
Basic function of sugar is that, it provides sweetness. Besides this, it enhances flavor and
aroma. It helps in browning by caramelization reaction and imparts color to
the bakery items. It also increases the product’s shelf life by increasing its
moisture retention. Sugar is not considered an essential ingredient in baking. This is
because flour contains a small amount of natural sugars
• Imparts sweetness
• Contribute to eating texture
• Increase crispiness of biscuit
• Browning effect
• Fuel for yeast
• Extents shelf life
 DEXTROSE:
• It is a simple sugar, can occur naturally in some food & honey but industrially
produced dextrose usually made from corn starch.
• Also helps in baking.
• Major role in taste, texture & color development.
 BUTTER:
Butter is made from cream and has a fat content of at least 80 percent. The remaining 20
percent is water with some milk solids. Butter imparts a good flavor without a greasy mouth
feel to baked goods because it melts at body temperature. It adds valuable nutrients to the
biscuits.
 EGGS:
Serve many functions in baked goods. They add flavor and color, contribute to structure,
incorporate air when beaten, provide liquid, fat, and protein, and emulsify fat with liquid

ingredients. Reducing or omitting egg yolks can result in less tenderness. If a low fat, low
cholesterol baked product is desired, use 2 egg whites for 1 whole egg; the white has very
little fat or cholesterol. When a recipe calls for an egg, the best size to use is a 2 oz. Grade A
large eggs.
• Eggs contribute flavor to the product.

• Act as emulsifier
• Helps in smooth & even texture of the finished product
• Contributes to the structure of baked product
• Contribute color, nutritional value & desirable flavor
• Improves characteristic organoleptic qualities of biscuit
 ARTIFICAIL FLAVORS:
These are used toad or enhance flavor of product. Good quality flavors must be used.
• Primarily used to improve the flavor of the product
• Used in dough & cream
• Different flavors used in biscuit making are vanilla flavor, strawberry flavor, chocolate
flavor, peanut flavor, lemon, butter milk flavor, butter flavor, condensed milk flavor,
mango flavor etc.
 COCA POWDER:
An unsweetened powder made from the left over chocolate liquor. The chocolate liquor is
made from cocoa beans & about 75% of it is extracted as cocoa butter and the remaining is
bright and ground into cocoa powder. It is used to add chocolate flavor to baked goods.
 SMS (SODIUM METABISUPHITE)

• Used in very small quantity to modify the gluten quality chemically.

• It causes the gluten to become more extensible & less elastic, therefore reduces the
shrinkage of dough pieces as they are baked
• It is useful processing aid to compensate for the variations in gluten quality
BISCUIT SECTONS
FLOW DIAGRAM:
Raw material Lab analysis Storing Weighing & sifting
Cooling Baking Rolling and shaping Mixing
Stacker Sorting & packing Storing Dispatch
PROCESSING LINE FOR BISCUITS
1. Raw material:
Raw material used for different biscuits is received at factory and is analyzed as described in
lab work section.
2. Lab analysis:
All raw material is analyzed in Lab and those materials which fullfil the standard
requirements are then used.
3. Storage:
If raw material passes the reception tests then it is stored in storage room. Proper storage is
necessary to avoid contamination and for quality of end product. As for flour, the bags should

be at least 1.6 feet away from walls and roof. This distance should also be between the rows.
The other raw materials are also stored properly.

Weighing & sifting:
• Scale all ingredients accurately.

• Sift the dry ingredients together into a mixer.
4. Mixing:
• Combine the liquid ingredients.

• Add the liquid to the dry ingredients. Mix just until the ingredients are combined
and soft dough is formed. Do not over mix.
• The mixing temperature should be 25 to 29°C.
5. Metal detector (CCP):
A metal detector is present before the cutting Its function is to detect the metal or other
contaminants from ingredients or at previous steps of manufacturing process.
All products must pass through correctly functioning metal detector.
Industry sets standards for detection of metal pieces. It is checked daily and after each hour
and quality sheet is filled.
6. Rolling and Shaping/ Cutting:
After proper mixing, the dough is dropped in the hopper. Here the rollers present in the

hopper make the small fragments of dough. The conveyor belt carries these fragments
towards the mould. The rolling mould then forms and cuts biscuits into the shape made on the
mould. All this process is handled mechanically. Also this process can be carried out by wire
cutter.
7. Baking:
It is the technique of prolonged cooking of food by dry heat acting by convection, normally in
an oven, but also in hot ashes, or on hot stones.
The raw prepared biscuits enter in oven through conveyer. Where they are heated at
temperature 240 to 245°C. This is a continuous mechanical process. The biscuits remain
within oven for 5 minutes. This is a general scheme. The time can be varied due to variation
in weight.

 Cooling:
After baking, cooling is done. A cooling under controlled conditions ensures a perfect and
lasting preservation of the packed biscuits. By mounting a special mesh belt-shifter, no
sideslip is possible. The forced cooling is obtained by air-flow line with centrifugal fan. All
necessary safety devices and sanitary materials are used. Cooling is done at room temperature.
The biscuits move on a long belt at room temperature which cools the biscuits. The cooling
time can be increased or decreased by changing the speed of the cooling belt.
 Stackers:
The function of stacker is that it makes arrangement of biscuits which facilitates in

further operations.
In this step the following things are

assured that
• The weight of 10 biscuits
according to standard
• There is no color variation.
• The biscuits are sound and
separate from each other.
• The diameter is according to
standard

 Packing:
The biscuits are manually placed in plastic tray and are packed mechanically in wrappers.
Then the packets are packed in boxes and then are covered by cellophane paper.
The Mfg. and Expiry dates are mentioned on the packing.
The following particulars should be clearly and indelibly marked on label on each pack:
(a) Name or trade-name of the biscuit,
(b) Name of the biscuit manufacturer,
(c) Batch or code number,
(d) Net weight in grams (g) or kilograms (kg), and
(e) The statement ‘Permitted flavoring and coloring agents used”
 Storing:
The finally packed product is stored in ware house or dispatch room.
 Dispatching:
Then the product is dispatched to market.

 Quality defects in biscuits:
• Over baked
• Under baked
• Small diameter
• Broken biscuits
• Fin seal and end seal problems
• Wrapper printing problems
WAFERS SECTION
WAFERS:
It is a small crispy food product which is filled with layers of flavored cream. Wafers are a
very specialized type of biscuit requiring special equipment for production. The sheets formed
by baking between pairs of heated metal plates, which are like large steel book leaves at one
side, are typically thin and usually bear intricate surface patterns with deep relief derived from
the baking plates. Wafers which are sold in biscuit markets are usually formed as large flat
sheets which are rigid as they come from the oven and these are subsequently sandwiched
with cream or caramel before cutting with saws or wires. They may be chocolate enrobed or
included in molded chocolate
INGRIDIENTS:
• Water
• Wheat flour
• Grinded sugar
• Corn oil
• Cream
• Salt

• Soya lecithin
• Artificial color
• Sodium bicarbonate
• Skimmed milk powder
• Dextrose powder
• Antioxident
FLOW DIAGRAM:
Raw material Lab analysis Storing Weighing & sifting
Cooling Baking Sheeting Mixing
Creaming Cutting & enrobing Packaging Dispatch

`
 PROCESSING LINE FOR WAFERS:

 Raw material:
Raw material used for wafers is received at factory and is analyzed. Most of the ingredients in
biscuits and wafers are same. There are differences in processing.
 Lab analysis:
All raw material is analyzed in Lab and those materials which fullfil the standard
requirements are then used.

 Storage:
If raw material passes the reception tests then it is stored in storage room. Proper storage is
necessary to avoid contamination and for quality of end product.
As for flour, the bags should be at least 1.6 feet away from walls and roof. This distance
should also be between the rows. The other raw materials are also stored properly.
Weighing & sifting:
• Scale all ingredients accurately.

• Sift the dry ingredients
 Mixing:.
• Add chilled water in the mixer.

• Add the dry ingredients to water in the mixer.
• Mix them until the ingredients are uniformly mixed. Do not over mix. It takes
about 8-10 minute to mix properly.This gives us batter.
 Baking:

Then this batter is shifted to the dies of the oven. The batter is transferred through a nozzle by
pumping.
Here it is heated at 150°C for three and half minutes. The heated die bakes, gives specific
shape and forms sheet of the wafer.
 Cooling:
After baking these sheets are cooled on the moving belt. It takes about two and half minutes
for cooling. Then these sheets are transferred to the creaming section. Here the broken sheets
are separated from sound ones. The weight of 3 plane sheets after cooling should be 120 to
125 gram.
 Creaming:
The cream is spread on a roller of the creaming machine from the hopper. The sheets pass
under this creaming roller and get creamed.
The machine is automatically set. Two sheets with cream and one without are attached to each
other. Here the weight of sheets with cream should 270 to 280 gram.

o Creaming method:
The cream is prepared in a separate cream mixing machine from where it is transferred to the
hopper of creaming machine.
For cream preparation cream, sugar, color and flavor are added and mixed for three minutes in
a cream mixer. The following ingredient is also used during mixing:
• Cocoa powder for chocolate cream

• Vanilla powder for vanilla cream

 Cutting:
The sheets are cut with a cutting machine and the sound wafers are shifted to the packing
section.
 Enrobing:
Chocolate coated wafers are enrobed in chocolate.
 Packing:
The wafers are manually placed in plastic tray and are packed mechanically in wrappers. Then
the small packkets are packed in large packaging and then are covered with cellophane paper.
The Mfg and Expiry dates are mentioned on the packing.
The following particulars shall be clearly and indelibly marked on label on
each container:
(a) Name or trade-name of the biscuit,
(b) Name of the biscuit manufacturer,
(c) Batch or code number,
(d) Net weight in grams (g) or kilograms (kg), and
(e) The statement ‘Permitted flavoring and coloring agents used.

 Storing:
The finally packed product is stored in ware house or dispatch room.
 Dispatch:
Then the product is dispatched to market.
Requirements:
• Wafers will be properly baked and will not show signs of under baking or over
baking.
• They will be crisp, crunchy and light in texture. The design impressed on them, if
any will be clear.
• They will have an agreeable odor typical of well-baked wafers, and will be free
from soapy or other objectionable flavors.
• They will not have insect and fungus infestation.

CHOCOLATE: This section was not functional due to summer
session
LAB WORK:
In lab all the raw material and finished products are tested if fulfill the mention criteria
than it is used. In lab following raw material are analyzed.
Sr Raw material Quantity No of Analysis Standard for

# samples Acceptance
1 Ammonium 50 bags 2 bags Solubility 100%
bicarbonate Purity
(Ammonia)
2 Brown sugar Moisture % 0.5 %
Ash % 0.1%
Color Brown
Granulation Uniform fine crystals
of sugar
Solubility 100 %
3 Bran 20 bags 2 bags Moisture%
(choker) Ash %
Substandard %
4 Chocolate chips 15 tn Random Substandard 5 specks in 100 gram
sampling max
from the lot No. of pcs in 10 80-90 pcs
gram
5 Cocoa powder 100 bags Random Moisture -
200 bags sampling Smell Chocolate smell
from the Appearance Dark brown finer
whole lot powder without caking
6 Colors - - solubility 100%
7 Dessicated 20 bags 2 bags Moisture 3-4 % max
coconut FFA 0.3% max
Rancidity Nil
Fat % 60- 65 % (range)

Color Natural white
Smell Free from rancid,
musty or objectionable
odor
Taste Mild and sweet coconut
taste with no off flavor
Impurities No more than 5 dark
specks in 100 grams
Granulation Uniform granules
8 Dextrose 100 bags 4 bags Moisture 10 % max
Solubility 100%
Color White
Taste Light sweet
Appearance Crystalline fine
granules/ powder
9 Desi ghee 10 tin 1 tin FFA 0.1 % max

(Tarkka) 20 tin 2 tin POV Nil
Rancidity Nil
SMP 39- 41 °C
SFI -
MFG/EXP date
10 Eggs 25 pati Inspection Physical No blood spot or
50 pati of the whole appearance dirt/dust etc
lot Substandard% 0.05%
Weight of 10 Min 500 g
eggs
11 50 kg Random Specific gravity
100 kg sample
12 Full cream milk 10 bags 1 bag Moisture 7 % max
powder 25 bags 2 bags Solubility 100%
(FCPM) 40 bags 3 bags Color White
50 bags 4 bags Taste Sweet with no off smell
Appearance Fine powder with no
caking
13 Flavo Liquid 100 L Random Specific gravity -
r sampling Smell Specific smell
from cans according to standard
Powder Smell According to the
standard
14 Golden syrup 10 cans Random moisture 18-22%
sampling Viscosity
from cans

15 Hellu syrup 10 can Random moisture 18-22%
sampling Viscosity
from cans
16 Lecithin 10 drum 1 sample Emulsion Uniform emulsion
formation formation
17 Liquid Glucose 100 cans Random moisture 18-22%
150 kgs sampling Viscosity
from cans
18 Oil 10 tin 1 tin FFA 0.1% max
20 tin 2 tin POV Negative (qualitative)
Rancidity Negative (qualitative)
SFI -
MFG/EXP date
19 Oat flour 10 bags 1 bag Sieving Zero tolerance for
(Jambo Atta) 20 bags 2 bags beetles and foreign
30 bags 3 bags maters
Moisture 14.5 % max
Ash 0.5 % max
20 Peanut 25 kg 2 bags Moisture% 5 % max
50 kg 3 bags Fat % 40-50 %
Smell Normal
Impurities No more than 5 dark
specks in 100 grams
Taste Fresh peanut taste
21
22 Salt 20 bags 1 bag Solubility test 100%
40 bags 2 bags Impurities test Nil
80 bags 4 bags Color White
100 bags 4 bags Appearance Fine powder
Purity 98%
Moisture % 0.5 % max
23 (SAPP) 5 bags 1 bags Solubility 100%
Sodium acid
pyrophosphate
24 Skimmed milk 10 bags 1 bag Moisture 7% max
powder 25 bags 2 bags Solubility 100%
(SMP) 40 bags 3 bags Color Off white to white
50 bags 4 bags Taste Normal without off
smell
Appearance Fine powder without
caking
25 Sodium 50 bags 2 bags Solubility 100 %
bicarbonate

26 Soya flour 10 bags 1 bag Sieving Zero tolerance for
20 bags 2 bags beetles and foreign
30 bags 3 bags maters
Moisture % 5 % max
Gluten % 0%
Ash % 5 % max
Fat % 20 % max
27 Starch 20 bags 1 bag Moisture % 13 % max
50 bags 2 bags Ash % 0.2 %
100 bags 4 bags pH value 4.5-7
200 bags 6 bags Smell No disagreeable smell
Color Pure white
Appearance Homogenous free
flowing powder
28 Sugar 50 bags 1 bag Moisture % 0.5 % max
100 bags 2 bags Solubility 100%
200 bags 4 bags Impurities Not more than five
400 bags 8 bags specks in 100 gram
600 bag 10 bags sample
Ash % 0.05 % max
Color Sparkling white
Granulation Uniform fine crystals
of sugar
29 Vegetable Fat 400 carton 4 ctn FFA 0.1 % max
800 carton 8 ctn POV Negative (qualitative)
1200 carton 12 ctn Rancidity Negative (qualitative)
SMP 38- 41 °C
SFI -
MFG/EXP date
30 Wheat flour 50 bags 2 bags Sieving Zero tolerance for
(Maida) 75 bags 3 bags beetles and foreign
100 bags 4 bgas maters
200 bags 5 bags Gluten % 8.2 – 9.8 %
Ash % 0.5 % max
MFG/EXP date Must be labeled
31 Whole wheat 10 bags 1 bag Sieving Zero tolerance for
flour 20 bags 2 bags beetles and foreign
(Atta) 30 bags 3 bags maters
Gluten % 8.2 – 9.8 %
Ash % 0.5 % max

32 Whey powder 10 bags 1 bag Moisture 7 % max
25 bags 2 bags Solubility 100%
40 bags 3 bags Color particular size Uniform
50 bags 4 bags Yellowish
Taste Normal
Appearance Dry and uniform
texture without caking
33 Zeera 30 bags 2 bags Impurities Seeds with max 10
Cumin seeds specks in 100 gram
Smell No off smell.
Appearance Dry and clean seeds
34 Zeera powder 5 bags 1 bag Moisture
Cumin powder 10 bags 2 bag Smell No off smell
Color Dark brown powder
WHEAT FLOUR ANALYSIS:

Flour is one of the most important and basic ingredients of the biscuits. The quality of the
product will depend upon the quality of flour. So in order to ensure the quality following test
are performed in laboratory.
1. Gluten Percentage
2. Moisture Percentage
3. Ash
GLUTEN TEST:
Wheat flour possess unique properties of forming Visco-elastic and resistant to extension
dough. Gluten is protein. Gluten is formed by two components.
Gliadin: Elasticity in dough is due to gliadin.
Glutenin: Resistant to extension dough is due to glutenin.
The above two fractions are when hydrated, gluten is formed.
On the basis of Gluten percentage, flour is divided into three categories.

1- 9-10 % Soft Flour
2- 10-11 % Semi-hard Flour
3- 11 % or more Hard Flour
In Biscuit manufacturing mostly soft Flour with less gluten percentage is required for most of
the varieties (soft dough biscuits and cookies) because in biscuit manufacturing our objective
during mixing is not to develop gluten. That`s why mixing time is short and speed of mixing
is high. On the other hand, in bread industry, flour is mixed for long time and at low speed in
order to develop the gluten. But in biscuit industry, flour is added at the end and then a short
time mixing is given.
Gluten Test Procedure:

a) Apparatus
1. Petri dish
2. Mixing bowl
3. Glass container
4. Hard paper
5. Knife
6. Electric weighing balance
7. oven
b) Procedure
Take 20 grams of flour sample in a Petri-dish by using electrical balance. Put this sample in a
container for mixing. Add 10 ml water in it and start mixing it, preferably with one figure.
Keep on mixing and make its dough until flour sample is completely mixed and gluten is
formed. Then take water in the same container and dip the dough in it for 30 minutes after that
start washing sample dough. Washing is carried out in order to remove starch from it. Iodine
test can also be performed in order to check if starch is removed from sample dough. After the
removal of starch, take a small piece if hard paper and dry it. Weigh it and put the wet gluten
on it and spread on whole paper. After spreading, give it cuts with the help of a sharp knife.

Now place it in oven at 110 °C for the drying. When all the moisture is dried out, weigh it and
calculate the gluten % age.
c) Calculations
Weight of sample w1
Weight of hard paper w2
Weight of wet gluten w3
Wet gluten % age w3/w1 x 100
Weight of gluten and hard paper w4 = w2 + w3
Weight of gluten and hard paper after drying w5
Weight of dry gluten w6 = w4- w2
Dry gluten % age w6/w1 x 100
MOISTURE ANALYSIS:
Another important aspect of flour quality is the moisture percentage. Moisture percentage
affects the use of water in recipe. If moisture is high in flour, then less water will be used in
dough making and if moisture percentage of flour is low, then more water is required for the
dough making.
If the moisture percentage of the flour is high then the standard of the factory, then flour is
accepted for production on rebate.
Moisture Test (with Moisture Analyzer)

a) Apparatus
1. Moisture analyzer
b) Procedure

In modern method of moisture analysis, take 5 grams of the flour sample in a silver plate and
spread it in the plate. Put it in moisture analyzer at a temperature of 105 0C. Moisture analyzer
will show moisture percentage in few minutes.
Moisture % age =11.20%
Moisture Test (with Oven)
a) Apparatus
1. China dish
2. digital weighing balance
3. Oven
4. Holder to put out the hot china dish from the oven
5. Desiccator
b) Procedure
Take a china dish and place it in the oven for a few minutes. Then take it out of the oven and
place in the Desiccator till it cools down. Weigh the china dish. Set the oven temperature of
110 0C for two hours. Collect the 5 grams sample in china dish. Put the sample in oven. After
two hours draw the sample from oven. Put the sample in to Desiccator for a few minutes with
the help of a iron holder, than weigh the sample. Repeat this process three or four time, until
received the constant weight.
c) Calculations
Weight of sample w1
Empty plate weight w2
Weight of china dish and sample before drying w3= w1+ w2
Weight of china dish and sample after drying w4
Net sample weight w = w3 – w4
Loss of moisture w1-w
Moisture % loss of moisture x 100 /Sample weight

ASH TEST:
a) Apparatus
1. Crucible
2. digital weighing balance
3. Oven
4. Hot plate
5. Fume hood
6. Holder to put out the hot crucible from the furnace
7. Muffle furnace
8. Desiccator
b) Procedure
Take a crucible and place it in oven for a few minutes. Take crucible out of the oven and
place it in the Desiccator till it cools down. Weigh the crucible on digital weighing balance.
Take 10 gram flour sample in that crucible and place it on the hot plate in the fume hood,
charring is done until no fumes come out of the flour sample. Charred sample is than placed
in the muffle furnace at 550 °C for 4-5 hours until the flour sample turns into white ash. Take
out the sample from the muffle furnace and place it in the Desiccator till it cools down. Take
weight of the ash.
c) Calculations
Weight of sample w1
Empty crucible weight w2
Weight of crucible and sample before ashing w3= w1+ w2
Weight of crucible and sample after ashing w4
Net weight of ash w = w3 – w4
Ash % Weight of ash X 100 / Sample weight
= (w/w1) x 100

FAT (SHORTENING) ANALYSIS
Fat is used in biscuit for many reasons like it make the product more palatable, helps in
baking, helps in the formation of crisp along with the other ingredients.
Following tests are performed in fat:
1. Free Fatty Acids (FFA)
2. Rancidity
3. Slip Melting Point (SMP)
FREE FATTY ACID (FFA) TEST:

Free fatty acids are tested in the fat coming to the industry before using in production. This
test is performed because it is an indicator of time taken by the product to be rancid. If FFA of
the fat is high the product made from it will get rancid soon as compared to the fat with less
FFA. FFA can combine with the oxygen in the environment and product gets rancid as a
result.
a) Apparatus
1. 3 glass cylinders(50 mL)

2. 250 mL flask
3. 3 pipettes
4. Sucker
5. 50 mL burette
6. Digital weighing balance
b) Chemicals
1. Ethanol
2. Fat sample
3. Di-ethyl ether
4. 1% Phenolphthalein solution
5. 0.1N KOH solution

c) Procedure
Take 25 ml of Ethanol and 25 ml of Di-ethyl ether in flask. Add 2-3 drops of phenolphthalein
indicator solution and shake it. Then titrate it against 0.1N KOH till light pink color appears.
This is done in order to neutralize the solution. Then take10 grams sample of fat in the same
flask, and mix it.
The burette must be prepared before using. First, rinse the burette with distilled water. Close
the stopcock and put 10 mL of KOH in the burette. Swirl the KOH so that all of the burette
has been coated with the KOH. Drain the NaOH through the tip. This first rinse is to coat the
burette with the solution. Close the stopcock and place another 10 mL KOH in the burette.
Swirl again and drain through the tip. The second rinse is to make certain that only your KOH
is on the inside of the burette and not water.
After preparing the burette, fill it with KOH solution. Drain some of the KOH solution down
to make sure the tip of the burette is filled with NaOH and no air bubbles are in the tip or
drops hanging out of the tip. Air bubbles can be removed from the tip by thumping the tip
while the solution is flowing. Dry the tip of the burette and check to see if the burette is
leaking.
In this experiment the burette contains KOH.Titrate the fat solution until the colorless end
point appears.
d) Calculations
Weight of fat sample w
Initial reading of burette V1
Final reading of burette V2
Volume of KOH used V= V2- V1
FFA% 2.82 x V/w
RANCIDITY TEST:
Apparatus
1. 100 mL flask
2. Scapula
3. Three pipette

4. Sucker
5. Test tube with stopper
6. Digital weighing balance
7. Test tube holder
8. Test tube stand
9. Oven
Chemicals
1. Fat sample
2. 37% conc. HCl
3. 0.1% Phloroglucinol (solution made in ethanol/ether solvent)
Procedure
Take a small amount of fat sample in the flask with the help of specula. Take it in oven for
some time so that it melts completely. Take 5 grams of molten fat in test tube and add 5 gram
37% concentrated HCL. Shake and add 5 grams of Phloroglucinol (0.1 %). Again shake and
observe the color. Change in color will be rejected. If color match with original sample then it
is ok.
Rancidity in the given sample = Nil
SLIP MELTING POINT TEST:

Melting point is checked in order to check the behavior of fat in the product. If melting point
is low then, fat in the product will melt at lower temperature thus affecting the quality of the
product. If the melting point is high then it will affect the baking process during production.
a) Apparatus
1. Test tube
2. Test tube holder
3. Test tube stand
4. Burner
5. Two capillary tubes
6. Thread

Procedure
Take a test tube and put some fat sample in it and melt it on the burner while holding it with
the test tube holder. When all the fat in the test tube melts pace it in stand. Take tow capillary
tubes and dip their one end the melted fat sample. Take ½ - 1 inch of the sample in them and
put these capillary tubes in freezer for about five minutes.
Then take water bath and arrange the temperature of water bath to 10 °C or less than this. Tie
these capillary tubes with the thermometer and put them in the water bath and in the water
bath. Temperature will start rising. When fat will melt, it will slip and move in upward
direction, note this temperature carefully.
SMP of the given sample.
ANALYSIS OF FINISHED GOODS

 Physical characteristics:
• Color
• Weight
• Diameter
• Thickness
 Moisture
 Total Ash
 Fat
 FFA
 Cream%

Sr Finished No of samples Analysis Standard for
# products Acceptance
1 Biscuits Random sampling after Moisture 2.0 % max
every two hours Ash 0.05%
Fat According to the
product
FFA test 0.1% max
Over all According to the

packing standard
Water test No air leakage
Packet wt According to the
standard
2 Wafer Random sampling after Cream % According to the
every two hours Over all standard
packing According to the
Water test standard
Packet wt No air leakage
According to the
standard
Chocolate Random sampling after Over all According to the
every two hours packing standard
Water test No air leakage
Packet wt According to the
standard
PHYSICAL TESTS OF BISCUITS

1. Weight test
10 biscuits are taken from the line randomly. Then the weight is taken by the digital weighing
balance. The weight of both unbaked and baked biscuits is taken.
2. Diameter test
To determine the diameter (D), six cookies were placed edge to edge. The total diameter of
the six cookies is measured in mm by using a ruler. The cookies are rotated at an angle of 90°
for duplicate reading. This is repeated once more and average diameter is reported
in millimeters.
3. Thickness test

To determine the thickness (T), six cookies are placed on top of one another. The total height
is measured in millimeters with the help of ruler. This process is repeated thrice to get an
average value and results are reported in mm.
4. Moisture Test
Moisture of the finished products (biscuits) is tasted by moisture analyzer. Take biscuits and
grind them in grinder and take 2-3 grams in silver plate and place in moisture analyzer and
note the moisture percentage.
Moisture % age of sample =0.82%
5. Total Ash Test

Total ash is determined by muffle furnace. Ignite the sample at a temperature of 550 °C for 5-
6 hours.
Weight of china dish 53.0861 grams
Weight of biscuits 10.00 grams
Weight of china dish + Ash (After ignition) 53.1572
Ash % 53.0861/53.1572x100
0.07 %
Fat test
The biscuit is first ground to extract its fat. The fat% of biscuits is determined by
1. Soxhlet apparatus.
2. By dissolving in diethyl ether
Soxhlet Apparatus Method
a) Apparatus
1. China dish
2. Digital Weighing balance
3. Desiccator
4. Oven
5. Thimble/ filter paper

6. Soxhlet apparatus
b) Chemicals
Petroleum ether
c) Procedure
Take 5 grams for ground biscuit sample in a china dish. Place it in oven for 24 hours at 105
°C to remove its moisture. Then weigh the sample after drying and wrap it in a pre-weighed
filter paper so tightly that it should not leak form filter paper.
Place the filter paper inside the Soxhlet apparatus. Fill 2/3rd part of the round bottom flask
with petroleum ether. Switch on the heater to start fat extraction from the biscuit sample.
When the extraction is completed, take out the filter paper form the Soxhlet apparatus. Place it
in the oven for a few minutes to evaporate the petroleum ether residues in the sample. Than
weigh it.
d) Calculations
Weight of sample after drying w1
Weight of filter paper w2
Weight of sample and filter paper w1 +w2
Weight of sample and filter paper after fat extraction w3
Weight of sample after fat extraction w4= (w1 +w2) - w3
Weight of fat in biscuit = w1 – w4
Fat% w/w1 x 100
By Dissolving In Diethyl Ether

In second method, biscuits are grinded and then take this sample in a closed container. Add
sufficient amount of diethyl Ether to dissolve fat present in biscuits. Now mix the biscuits in
diethyl Ether and dissolve fat in it. After dissolving fat, remove the diethyl Ether from the

container and pour in a Petri plat. Now dry it on the water bath until all the ether has been
evaporated. Now we have fat, extracted from biscuit
Food Packaging Material Analysis:

Food packaging is packaging for food. It requires protection, tampering resistance and special
physical, chemical and biological needs. It also shows the product that is labeled to show any
nutrition information on the food being consumed.
Sr Packaging No of samples Analysis Standard for
# material Acceptance
1 Film/ wrapper Random sampling from Reel Wirth, According to set
different Reels Length, standards
Thickness,
color, moisture
2 Box Random sampling from Weight, width, According to set
different places length, standards
(5-10 % boxes) grammage, lock
device,
moisture,
gumming,
color, creasing,
flap cutting
3 Carton Random sampling from Weight, width, According to set
different places length, standards
(5-10 % cartons) grammage, lock
device,
moisture,
gumming,
color, fluting,
creasing, flap
cutting
4 Tap Random sampling from Gum % 50 % minimum
different places(5-10 %
tapes)
5 Biscuit tray Random sampling (5-10 % Tray weight According to the
trays) Length standards
Wirth
Depth

List of Packaging material used in Biscuits industry:
1. Films
2. Family pack
3. Dispenser Box
4. Master carton
 QUALITY
Definitions:
Conformance to customer’s requirement or degree of excellence is called quality. The sum of
characteristics of a product which influence the customer to accept or reject the product. The
totality of features and characteristics that bear on ability of a product to satisfy fitness for
use, including safety and performance.
Quality system:
The organizational structure, responsibilities, procedures, processes and resources for
implementing quality management.
Management system: System to establish policy and objectives and to achieve those
objectives.
Quality management system: System to establish quality policy and quality objectives and
to achieve those objectives.
Conformity: Fulfillment of requirements.
Non-conformity: Non fulfillment of requirements.
Quality control: Part of QMS focused on fulfillment of quality requirements. All corrective
measures are known as quality control. If biscuit color is dark after baking then we take a
corrective step that is quality control.
Quality assurance: Part of QMS which provide confidence that quality requirements are
being fulfilled. All the preventive measures are part of quality assurance. It include personal
hygiene, finished goods inspection safety measures etc.

QUALITY CONTROL AND QUALITY ASSURANCE
Quality control and quality assurance are very important for any of ISO & HACCP certified
company. At innovative, quality assurance inspectors control the quality by observing and
analyzing on different points of line from mixing to final packaging. Quality control and
quality assurance departments are same.
 Mixing:
At mixing, the mixing incharge note and write all the ingredients on register. He ticks
mark the ingredients when they are being poured in mixing machine. The quality control
inspector visit and note that all the ingredients are mixed in the batch or either of them is
missing. So mixing is first check point.
 Cutting:
On cutting the most important thing is the size of the biscuits. The biscuits may come
of small size or large size. QA inspectors notes the weight of ‘10’ biscuits and matches it with
the standard which is specific for each variety of biscuit. If there is problem in weight of
biscuits then at the time it is controlled by cutting incharge.
 Oven:
After that the biscuit enters in to the oven. Immediately when biscuit comes out of the
oven, it is observed for the shape, size i.e. length, width, thickness. For this purpose a gauge is
used. The size of gauge is specific for each variety of biscuit. Vernier calipers is also used to
measure biscuit parameters. The weight of ten biscuits is taken here again to assure the
quality. Here the biscuit’s weight is about 10 gram less than before entering to the oven
because 10g is moisture is evaporated during baking in oven and most of this moisture is
evaporated during first and second zone of oven because first zone is puffing zone, second in
baking zone and third is coloring zone.

 Packaging:
After oven, when product enters in packaging area, QA inspectors observe the
biscuits, which are over baked and under baked. Such biscuits are removed from stacking
conveyor and never allowed to pack in order to ensure quality. In packing unit efficiency of
packing machines are tested and controlled. When product is packed in family pack or in half
roll pack, the leakage in plastic film is observed by dipping the pack in water. If water enters
in the pack, this shows that product is not packed properly.
 Quality control reports:

1. Cutting section inspection report
2. Oven baking inspection repot
3. Packaging section inspection report
 Quality Assurance reports:

1. Personal hygiene inspection report
2. Finished goods inspection report
3. Plant sanitation inspection report
4. Raw material inspection report etc
 GMP’s:
Some of the tasks relating to GMP’s in which we took part include:
 Plant sanitation inspection

 Personal hygiene inspection
 Training of workers
 IPM

 Plant sanitation:
In plant sanitation daily inspection of plant cleanliness was done and quality sheets
were filled. Any non-conformity occurring was checked, noted and informed to the
related persons. The cleanliness of belts, stackers, product trays etc. was checked. A
proper place of everything was checked i.e. empty trays, trays containing the product,
tools, packing material etc.
 Personal hygiene & GMPs inspection:

In personal hygiene & GMPs inspection, daily inspection of workers was done and
quality sheets were filled. Any non-conformity occurring was checked, noted and
informed to the related persons.
It was checked that workers are wearing hairnets, clean uniform and shoes, using
gloves, have proper haircuts, trimmed nails etc.
No one is wearing jewelry and suffering from illness, eating or drinking in the
production hall etc.
 Training of workers:
Training of the workers is very important. The training of workers is done according
to schedule. The workers are taught about the basic definitions relating to ISO and
then evaluation is done in which they are asked about these definitions.
Further they are taught about personal hygiene and GMPs.
They were also given work instructions in order to efficiently perform their work
leading to quality.
 IPM (integrated pest management):
In Integrated pest management. We worked with the spray man and learned about
different activities to control the pests.
These are controlled by different methods as:
• Daily spray is done to control flying and crawling pests.
• Bait stations are used to control crawling insects.
• Glue boxes are used to control rats.

ASSIGNMENT # 1
Contents:
• What is IPM? What are steps for IPM?
• Which insects are found in food industry, their identification and life
spam.
• How many defense lines are present in Innovative and how any insects are
found in 24 hours?
• Conduct a GAP analysis regarding IPM in Innovative
Introduction:
A pest infestation can put your product and your business' reputation at
risk.
The goal of Integrated Pest Management (IPM) is to identify, prevent, and eliminate
conditions that could promote or sustain a pest population with a food manufacturing, storage,
or transportation operation. IPM relies on appropriate assessment, monitoring, and
management of pest activities.
Integrated Pest Management (IPM) is an effective and environmentally sensitive approach to

pest management that relies on a combination of common-sense practices. IPM programs use
current, comprehensive information on the life cycles of pests and their interaction with the
environment. This information, in combination with available pest control methods, is used to
manage pest damage by the most economical means, and with the least possible hazard to
people, property, and the environment. The IPM approach can be applied to both agricultural
and non-agricultural settings, such as the home, garden, and workplace. IPM takes advantage
of all appropriate pest management options including, but not limited to, the judicious use of
pesticides. In contrast, organic food production applies many of the same concepts as IPM but
limits the use of pesticides to those that are produced from natural sources, as opposed to
synthetic chemicals. Integrated pest management (IPM) is a broad based ecological approach

to agricultural pest control that integrates pesticides/herbicides into a management system
incorporating a range of practices for economic control of a pest. In IPM, one attempts to
prevent infestation, to observe patterns of infestation when they occur, and to intervene
(without poisons) when one deems necessary.
Insect pests are proven carriers of many known diseases and therefore pose a constant threat
to food manufacturers, food processing facilities, healthcare facilities and the hospitality
industry.
Steps for an Effective Integrated Pest Management Program:
In food processing environments, quality pest control is a must. A pest infestation can put
your product and your business’ reputation at risk because nobody wants to find something in
the product that’s not on the label. But pest management in such environments is also very
sensitive. Special precautions must be taken to keep pest control treatments from threatening
food safety. To better control pests while respecting a food plant’s sensitive environmental
needs, you need to apply the principles of integrated pest management (IPM).
IPM programs are successful for a simple reason. They recognize that pest management is a
process, not a one-time event, and that relying solely on chemical controls when so many
other tools are available is never the best solution. By addressing the underlying causes of
pest infestations – access to food, water and shelter – IPM can prevent infestation before
pesticides are even considered. In practice, IPM is an ongoing cycle of seven critical steps:
1: Inspection
The cornerstone of an effective IPM program is a schedule of regular inspections. For food
processors weekly inspections are common, and some plants inspect even more frequently.
These routine inspections should focus on areas where pests are most likely to appear –
receiving docks, storage areas, employee break rooms, sites of recent ingredient spills, etc. –
and identify any potential entry points, food and water sources, or harborage zones that might
encourage pest problems.

2: Preventive Action:
As regular inspections reveal vulnerabilities in your pest management program, take steps to
address them before they cause a real problem. One of the most effective prevention measures
is exclusion, i.e., performing structural maintenance to close potential entry points revealed
during inspection. By physically keeping pests out, you can reduce the need for chemical
countermeasures. Likewise, sanitation and housekeeping will eliminate potential food and
water sources, thereby reducing pest pressure.
3: Identification:
Different pests have different behaviors. By identifying the problematic species, pests can be
eliminated more efficiently and with the least risk of harm to other organisms. Professional
pest management always starts with the correct identification of the pest in question. Make
sure your pest control provider undergoes rigorous training in pest identification and behavior.
4: Analysis:
Once you have properly identified the pest, you need to figure out why the pest is in your
facility. Is there food debris or moisture accumulation that may be attracting it? What about
odors? How are the pests finding their way in – perhaps through the floors or walls? Could
incoming shipments be infested? The answers to these questions will lead to the best choice of
control techniques.
5: Treatment Selection:
IPM stresses the use of non-chemical control methods, such as exclusion or trapping, before
chemical options. When other control methods have failed or are inappropriate for the
situation, chemicals may be used in least volatile formulations in targeted areas to treat the
specific pest. In other words, use the right treatments in the right places, and only as much as
you need to get the job done. Often, the “right treatment” will consist of a combination of
responses, from chemical treatments to baiting to trapping. But by focusing on non-chemical
options first, you can ensure that your pest management program is effectively eliminating
pests at the least risk to your food safety program, non-target organisms and the environment.
You’ll also see higher pest control scores at audit time.

6: Monitoring:
Since pest management is an ongoing process, constantly monitoring your facility for pest
activity and facility and operational changes can protect against infestation and help eliminate
existing ones. Since your pest management professional most likely visits your facility on a
bi-weekly or weekly basis, your staff needs to be the daily eyes and ears of the IPM program.
Employees should be cognizant of sanitation issues that affect the program and should report
any signs of pest activity. You don’t want to lose a day when it comes to reacting to an actual
pest presence.
7: Documentation:
Since pest control can account for up to 20 percent of your total score, it’s imperative that
your IPM program is ready to showcase come audit time. Up-to-date pest control
documentation is one of the first signs to an auditor that your facility takes pest control
seriously. Important documents include a scope of service, pest activity reports, service
reports, corrective action reports, trap layout maps, lists of approved pesticides, pesticide
usage reports and applicator licenses.
To ensure that your IPM program reaches its potential, approach your relationship with your
pest management professional as a partnership. Open communication and cooperation
between you, your staff and your provider makes for a winning IPM program. The benefits
are fewer headaches, safer products and better audit scores.

COMMON INSECTS IN FOOD INDUSRTIES:
Typical
Common name Identification adult
lifespan
Forewings are light gray to brown with straight dark lines or 14 days
Almond moth banding near outer portion of wing, hindwing is light gray to
beige with fringe of hairs on margin, wing tips are rounded
0.51-0.83 in (13-21 mm) wingspan
All mosquito species have one pair of scaled wings with a pair 7-10 days
Mosquito of halteres. Mosquitoes have slender bodies with long legs.
While their size varies by species, most mosquitoes are smaller
than 15 mm in length and weigh less than 2.5 mg
1/4 inch long: dul gray with 4 stripes on thorax; 4th wing vein 7-45 days
House Fly sharpley angled.
Workers are all the same size, small, 1/8 inch long, Dark brown 45-60 days
Household Ants to shiny black, Petiole with 1 node, hidden by abdomen,
Thorax uneven in shape when viewed from side, Very strong
odor when crushed.
Body length of 7-9 inches, Coat of coarse shaggy brown hair, 23 months
Rats Blunt noses, Tail around 6-8 inches long, Blunt ended capsule
shaped droppings approximately 3/4 inch in length.

DEFENSE LINES IN INNOVATIVE BISCUITS (PVT) LTD
 PREVENTIVE ACTIONS:
1st Defense Line: In first defense line 20 bait stations are present along with
boundary wall of industry.
2nd Defense Line: In second defense line air curtains and buffer areas are used.
 CORRECTIVE ACTIONS:
3rd Defense Line: In third defense line Mechanical traps, Glue boxes (40 boxes),
Electric fly killers (EFK) are included.
4th Defense Strategy: In this category we use permitted sprays (“ATTACK” and
“GAURDIAN” outside the buildings and "GUARDIAN PLUS” inside the buildings)
and spot killing.
TOOLS:
a) Glue Boxes
b) Bait stations
c) EFK’s(electric fly killer)
d) Cages
e) Sprays
A. GLUE BOXES:
One of the more common methods of mouse control is known as a mouse glue trap. These
sticky mouse traps are designed to be cost effective and low maintenance when compared
with more hands on methods such as the application of rodenticides. Because they are non-
toxic. Glue traps are made using natural or synthetic adhesive applied to cardboard, plastic
trays or similar material. Bait can be placed in the center or a scent may be added to the
adhesive by the manufacturer. Glue traps are used primarily for rodent control indoors. Glue

traps are not effective outdoors due to environmental conditions (moisture, dust), which
quickly render the adhesive ineffective. Glue strip or glue tray devices trap the mouse in the
sticky glue. . This is one option if you don't want to kill the rat. Keep in mind that a glue trap
can result in a frightened, angry rat that will attempt to bite whoever takes the glue trap
outdoors. Glue traps are often placed inside a box for that reason. Once the rat has been
caught in the glue, the entire box can be taken outdoors so that no one comes in contact with
the rat. Glue boxes contain a plastic sheet and a gel is pasted on it. The gel which is used is
known as ATRARAT. Glue boxes are checked every day and if any rat is present then it is
trapped in box
Number of Glue Boxes: 37 glue boxes are present in Innovative
B. BAIT STATION:
Bait stations are basically black box with a trap inside. Mice and rats never see it coming. The
bait box acts as harborage and safe haven for mice and rats, and this style of trap plays a
safety role when children and pets are present.
Location: Bait stations are present inside the boundary walls. Bait station are not present
inside the plant because a poison is placed inside it which attract the rats.
Number of Bait Station: 27 Bait station are present in Innovative.
C. ELECTRIC FLY KILLERS:

The electronic fly killer in the form of the electric fly trap works on principle that they use
light which is a major source of attraction for flies, mosquitoes and other related bugs and
insects. The electronic fly killer, as the name suggests works only when there is a source of
electricity which activates the electric fly trap. This electronic fly killer along with giving out
a specific scent for the flies and insects to get attracted to also has a high beam light which is
the most favorable source for flies. The moment the flies sit on the electronic fly killer, they
are glued down to the plate and starve to death there only. Some of the electronic fly killer
also features a slight electric current which is passed on to the electronic fly killer board. This
makes the elimination of the flies and insects faster and less painful. The moment the
electronic fly killer is switched off, the dead flies are collected in a tray attached to the

electronic fly killer and can be disposed off easily. Some of these fly killer lamps also use
ultraviolet light to attract and kill the flies. This electronic fly killer is one of the best devices
for trapping flies, mosquitoes and other insects. The latest electronic fly killer is mainly made
out of stainless steel and is beautifully designed so that along with the utility factor, it also
adds to the décor of the room. They electronic fly killer is extremely efficient and is widely
used in offices, restaurants, home etc.
Number of EFK’s: There are present 22 EFK’s in Innovative.
LOCATION:
1. Sugar grinding area

2. Biscuit mixing section, in front of stairs
3. Biscuit mixing section, lift area
4. Biscuit mixing section, processing area
5. Biscuit cutting section, hand washing station
6. Biscuit cutting section, plant #1
7. Biscuit cutting section plant #3
8. Biscuit cooling section/chock-2 packing section
9. Biscuits packing section, near entrance
10. Biscuits packing section, near staff offices
11. Lock room- near plant stairs
12. Lock room- near outward stairs
13. Admin office
14. Dispatch section
15. Wafer sheet mixing section
16. Wafer sheet mixing section, change room
17. Wafer section, hand washing station
18. Wafer packing section
19. Packing material store
20. Electric workshop
21. Mechanical workshop

22. Molded chocolate section
D. CAGES:
A rat cage trap is a metal cage box-shaped device that is designed primarily to catch rats
without killing them. Food bait (not poisoned) is put in the cage trap. When an animal enters
the cage and moves toward the bait, the mechanism triggers and closes a door over the entry
point. The animal is caught alive and without injury. The animal can be transported and
released elsewhere or subsequently killed.
E. SPRAYS:
a) Attack
b) Gardian
c) Gardian plus
a. Attack:
In this active ingredient is Dichlorvos.it is sprayed on floors, lower parts of walls, around
baseboards or moldings, around door and window frames, in corners, in cracks or crevices, on
beds, behind or underneath objects, or within cabinets, cupboards, drawer spaces, closets, or
storage spaces, It is not sprayed in the production area. It kill flies, crawling insects, mosquito,
lizards.
b. Gardian:
In this active ingredient is Detta Methnin.it is sprayed on floors, lower parts of walls, around
baseboards or moldings, around door and window frames, in corners, in cracks or crevices, on
beds, behind or underneath objects, or within cabinets, cupboards, drawer spaces, closets, or
storage spaces, It is not sprayed in the production area. It kill flying and crawling insects.
c. Gardian Plus:
It is also sprayed in production area. It kill same insects as attack but it has no smell so it is
mostly sprayed inside the building e.g mixing areas, packaging areas, cooling areas

Insects found in 24 hours:
NO OF INSECTS
INSECT EQUIPMENT Day1 Day 2 LOCATION
53 70 New Hall
Mosquito EFK 24 29 Old Hall (Cutting)
1 3 New Hall
Flies EFK 2 1 Old Hall (Cutting)
15 9 Old Hall (Cutting)
Ants Glue Box 18 23 New Hall
Tiny bark beetles EFK, Glue Box 70 56 Old Hall (Cutting)
GAP ANALYSIS AT INNOVATIVE BISCUITS PVT. LTD REGARDING

INTIGRATED PEST MANAGEMENT
GAPS OBSERVED POSSIBLE SOLUTIONS
Lids of gutter on main road near security Proper covering of gutters
office are not closed properly that provide
breeding environment to mosquitos
Water standing and opened gutters before Drainage system on road

quality assurance laboratory
Water driving pipes ends are filled with water Proper covering of pipes or removal of
and not covered on main road from security whater
office
Bait stations are filled with dust and not Grains should be changed as needed
properly cleaned
Spraying only in main street and security Spraying at all around the processing hall
office and near generators area
Most of Glue box are empty Placement of paper having glue on it
No mechanical traps at store and Mechanical traps at store and cutting section

OLD HALL
Main entrance door to cutting has holes and Gap covering by welding
gap upside the door
Emergency exit of cutting section remain Buffer area construction
open
At the entrance of packaging department, on Close the hole so that rodent cannot enter
left side, hole for wire is not closed properly
Window no. 3 in packaging hall have hole Cleaning if windows as needed

and dust
Gap in door in packaging hall near lift That door should be closed as there is no
need for that
No glue boxes at packaging section’s doors There are doors that are direct opened in
street so glue boxes are necessary
Area near lift in not cleaned that is hiding After cleaning, accessing door should be
place for insects locked as no need to open that
Gap in main enternce to chockalate section There should be buffer area and wires should
from main street due to wire be passed through proper ways
New Hall
In cutting section at plant no 4, 5 electrical Pipes should be closed as they allow entrance
trays and pipes are not closed properly of insects and pests
In cutting section, near conver no. 11,12,14 Pipes should be closed
pipes are not closed
In cutting section, near entrance door from Wall cracks should be filled
lab, wall has cracks
Washing inside the cutting section Washing should outside processing area
Trays not washed Unwashed trays should be kept outside
processing area

Raw material on floor near pillars Repairing of floor or proper cleaning of floor
cracks
Window no 3 in cutting section is opened Windows should be closed as they have small
holes that cannot stop insects
Window no 20 in baking hall has no glass Windows should be closed
and 2,3,5,23 are not properly closed
Emergency doors have holes and gaps in Gap should be filled with brush or any other
packaging section material
Uncovered hole in wall due to new plant in Proper wall should be constructed or removal
new hall packaging section of trays and proper closing of holes with
sheet
Door mostly remains opened and direct There should be buffer area or it should
opening in packaging section beauto closing door
Wafer Section
Gap in door and window used for conveying Filling of gaps
goods in mixing section
5 holes in roof in mixing section Repairing of roof
Chocos Section
In mixing section, beneath stairs, hiding place This place should be cleaned
for insects is not cleaned
2 holes and small gap in cutting section Gap should be removed
entrance door
No buffer area Buffer area should be there

ASSIGNMENT # 2
Contents:
 Role of fat, sugar, water and flour in biscuits.
ROLE OF FAT IN BISCUITS:

Fat in the form of solid shortening, margarine, or butter; or in the liquid form of oil
contributes tenderness, moistness, and a smooth mouthfeel to baked goods. Fats enhance the
flavors of other ingredients as well as contributing its own flavor, as in the case of butter. In
baked goods such as muffins, reducing the amount of fat in a recipe results in a tougher
product because gluten develops more freely. Another tenderizing agent such as sugar can be
added or increased to tenderize in place of the fat. A small amount of fat in a yeast dough
helps the gluten to stretch, yielding a loaf with greater volume.
Shortening:
Shortening is 100 percent fat and is solid at room temperature. It is often made of
hydrogenated (solidified by adding hydrogen) vegetable oils, but sometimes contains animal
fats. The flakiness of pastry comes from solid fat such as shortening or lard rolled in layers
with flour. In some recipes for cookies or cake, shortening is creamed with sugar to trap air. A
lighter product will result. There are emulsifiers in shortening to help emulsify shortening and
liquid. This means that oil and water stay mixed together, creating an even distribution of
flavors and a consistent texture in batters and dough.
Butter:
Butter is made from cream and has a fat content of at least 80 percent. The remaining 20
percent is water with some milk solids. Butter imparts a good flavor without a greasy mouth
feel to baked goods because it melts at body temperature.
Margarine:
Margarine is made from fat or oil that is partially hydrogenated, water, milk solids, and salt.
Vitamins and coloring are usually added also. The fat or oil can be of animal or vegetable
origin. Margarine has the same ratio of fat to non-fat ingredients as butter (80:20), and can be
used interchangeably with butter.
Reduced fat substitutes:

Reduced fat substitutes have less than 80 percent fat. These do not work the same as butter or
margarine in baked goods, though some specially formulated recipes can be found on the
packages of these products. Fat free margarines also are available and contain no fat. These
margarines are best used as spreads.
Oil:
Oil is used in some muffin, bread and cake recipes. Oil pastry is mealy rather than flaky. To
substitute oil for butter or margarine, use 7/8 cup oil for 1 cup butter or margarine. If oil is
used in place of a solid fat for some cake recipes, the texture will be heavier unless the sugar
and egg are increased
ROLE OF FLOUR:
Flour provides the structure in baked goods. Wheat flour contains proteins that interact with
each other when mixed with water, forming gluten. It is this elastic gluten framework which
stretches to contain the expanding leavening gases during rising. The protein content of a
flour affects the strength of a dough. The different wheat flour types contain varying amounts
of the gluten forming proteins. Hard wheat, mainly grown in the mid west of the U.S. has a
high protein content. Soft wheat, grown in southern U.S. has less protein.
Cake flour is a soft wheat flour that is 7.5 percent protein. The lower gluten content causes
products to have a tender, more crumbly texture that is desirable in cake.
All purpose flour is blended during milling to achieve a protein content of 10.5 percent. This
medium protein flour can be used for all baking purposes. If using all purpose flour in place
of cake flour in a recipe, substitute 1 cup minus 2 tablespoons all purpose flour for 1 cup cake
flour.
Whole wheat flour may be substituted for part of the white flour in yeast and quick bread
recipes, but the volume of the finished product will be reduced. Whole wheat flour contains
the nutritious germ and bran as well as the endosperm of the wheat kernel. Bran particles cut
through the gluten during mixing and kneading of bread dough, resulting in a smaller, heavier
loaf. If substituting a very coarsely ground whole wheat flour for all purpose flour, use 1 cup
plus 2 tablespoons whole wheat flour for every cup of all purpose flour. To substitute whole

wheat flour in a white bread recipe, use half whole wheat and half bread flour for the best
results.
Wheat germ, though not a flour, is often used in place of part of the flour in recipes for flavor
and fiber. Protein, vitamins, minerals, and polyunsaturated fats are concentrated in the germ
of grain kernels. Wheat germ, preferably toasted, can be used in place of up to 1/3 of the flour
in a recipe. The following non-wheat grain products are often used in baked goods. They are
rich in protein but most do not have the potential for developing gluten.
Rye flour is often used in combination with wheat flour for bread. Light rye flour can be
successfully substituted for 40 percent of wheat flour in a recipe without loss of volume.
Medium and dark rye flours should be limited to 30 percent and 20 percent, respectively, of
the total flour amount.
Triticale flour is a hybrid of wheat and rye. It has an average protein content higher than that
of wheat flour. In yeast bread dough, triticale flour has better handling properties than rye
flour because it will form gluten, but does not handle as well as wheat dough. For a good
quality dough, ferment yeast dough made with Triticale flour for a shorter period than wheat
flour dough.
Oat flour has relatively high protein content, 17 percent, but does not form gluten. Oat flour
can be substituted for as much as 1/3 of wheat flour in bread.
Corn meal is coarsely ground dried corn. Corn flour is more finely ground corn. Both corn
flour and corn meal contain 7-8 percent protein on a dry basis. Neither corn meal nor corn
flour will form gluten. A grainy texture in cornbread can be avoided by mixing the cornmeal
with the liquid from the recipe, bringing to a boil, and cooling before mixing with the other
ingredients.
Rice flour has about 6.5-7 protein and does not form gluten. For people who do not tolerate
gluten, rice flour is an acceptable substitute for wheat, barley, rye or oat flours. In baked
products, 7/8 cup of non-waxy rice flour can be used in place of 1 cup all-purpose wheat
flour. Soy flour contains 50 percent protein and is used primarily to boost the protein content
of baked goods. Soy flour cannot form gluten and does not contain starch. Its use in large
amounts affects the taste of baked goods and causes them to brown quickly. An acceptable

substitution is to take 2 tablespoons flour out of each cup of flour in a recipe and add 2
tablespoons soy flour.
ROLE OF SUGAR
Sweeteners are one of the most important ingredients used in bakery foods. While there are
many different sweeteners available, A large variety of sugars can be produced by extracting
and purifying sugar from sugar cane and sugar beet. These sugars may differ in colour,
flavour, sweetness, and crystal size. For example, the molasses in brown sugar gives it a
different flavour and appearance compared to granulated white. Sugar can also be used in
both crystalline and liquid forms. All of these characteristics contribute to the variety of
functions performed by sugar in foods. Sugar not only makes foods taste sweet, it also has
many other functions.
Sensory Properties
Sweetness is generally the most recognized functional property of sugar. The preference for
sweetness is thought to be innate, appearing shortly after birth. Perception of the relative
sweetness of sugar depends on factors such as temperature, pH, concentration, presence of
other ingredients, and the difference in individuals’ ability to taste (e.g., detection threshold).
Sugar is an important contributor to flavor by interacting with other ingredients. Depending
on the food application, sugar has the unique ability to heighten flavor or depress the
perception of other flavors. In breads, for example, the resulting flavor typically is due to two
processes that involve sugar In bakery products, sugar is recrystallized as water is removed
during baking, resulting in a crisp texture. This crispness is increased by the effects of
browning. Two different reactions are responsible for crust browning: caramelization and the
Maillard reaction. Caramelization results from the melting of sugars to create a deep brown
color and new flavors. The yellow-brown colors that developing baked foods can be attributed
to the presence of sugar. Sucrose itself develops color through caramelization. In addition,
sugar can be broken down into its two monosaccharide units (glucose and fructose), which
can take part in the Millard reaction and add to browning. Sugar also contributes to the color
of preserves and jellies through its capacity to attract and hold water. By absorbing water
more readily than other components, such as fruit, sugar prevents the fruit from absorbing

water.
Sugar acts as an important tenderizing agent in foods such as baked products. During the
mixing process, sugar competes with other ingredients for water. In bread-making for
example, the affinity of sugar to bind to water will delay the development of gluten, a protein
in grains that is essential for maintaining a soft or tender product. Gluten strands, in general,
are highly elastic, and this property allows the batter to stretch under the expansion of gases.
Too much gluten formation, however, will cause the dough or batter to become rigid and
tough. When the correct proportion of sugar is added in the recipe.
Physical Properties:
The physical functions that sugar contributes to foods include its solubility in water, its ability
to lower the freezing point and raise the boiling point. Solutions of varying sugar
concentrations are important in many food applications, including the production of jellies
and jams. Freezing point depression is an important property in ice creams, frozen desserts,
and freeze-dried foods to ensure the development of fine crystal structure and product
smoothness.
Microbial (Food Preservation and Fermentation)

Sugar plays an important role in extending the shelf life of bakery products. Sugar can bind to
water molecules, slowing moisture loss and preventing staleness in baked goods. In addition,
the glucose/ fructose mixture in invert sugar present in jams and jellies helps to inhibit
microbial growth and, later, spoilage.
Fermentation, an extremely important process in the baking industry, is fuelled by sugars.
Sugars are used to activate yeast for fermentation. The type and amount of sugar added can
increase the dough yield and softness of bread by altering the rate of fermentation. When a
hard crust bread is desired, sugars are either omitted or used in lower quantities. In this case,
the yeast is activated by sugars formed when starch is broken down by enzymes present in the
flour. Sugars remaining after fermentation contribute to the overall flavour, colour, and
texture of the final product.

ROLE OF WATER:
Water is a basic ingredient in baking. It would be impossible to produce biscuits without

water in some form. It facilitates mixing of ingredients and other steps of processing. There
are certain functions of water which include:
• It makes possible the formation of gluten.

• It wets and swells the starch.
• It assists in controlling the temperature of dough a through adding cold or warm water
the temperature of the dough can be regulated.
• It dissolves salts, suspends and distributes non-flour ingredients uniformly.
ASSIGNMENT #3
Contents:
• What are line clearance activities (SOPs) and operational time of line.
• Problems observed at stacker and during packaging.
 LINE CLEARENCE ACTIVITIES (SOPs)

Activities (SOPs) at cutting section:
 Belts and Hopper are cleaned.
 Mixer is cleaned.
 Hopper is cleaned.
 Dough feeding conveyer is cleaned.
 Die is cleaned or changed accordingly.
 Roller of die are cleaned with air pressure.
 Stiching of belt is checked.
 Floor is cleaned.
 Temperature of room and dough are checked.

Activities (SOPs) at oven section:
 Oven temperature is adjusted.
 Wasted is cleaned and stacked into yellow trays.
 Steel belt is cleaned with dough so that product bottom do not get contaminated by
burnt residues of biscuits, baked before.
 Stiching of cooling conveyer belt are checked.
 Rollers are cleaned.
Activities (SOPs) at stacker:

 Diameter of stacker rows are adjusted.
 Rework trays are cleaned.
Activities for packaging section:

 Reels of packaging machines are checked.
 Waste/ rework trays are cleaned.
 Packaging machine is cleaned for any residues of already packed product.
Operational activities
 Cutting started at 7:50 AM
 Time when first row came out of oven = 7:59 AM
 Time when product reached at stacker = 8: 06 AM
 Packaging material issued at 8:00 AM
 Labor online at 8:30 AM
 PROBLEMS OBERVED AT STACKER AND DURING

PACKAGING
Problems observed at stacker:
1. Dark color biscuits
2. Edges of biscuits are broken
3. Light color biscuits

4. Length problem
5. Diameter less/more
6. Low weight
7. Over weight
8. Height problem
9. Thickness problem
Problems observed during packaging:

1. Fin seal and side seal are not properly sealed
2. Loose packaging
3. Eye mark problem
4. Air leakage
5. Broken biscuits within packets
6. Date printing problem
7. Packet burnt due to high temperature
8. Empty packets
9. Short filling /Over filling
ASSIGNMENT # 4
• CPM of cutter and temperature of dough
• CCPs in biscuit plant
• Calculate baking loss
CPM of cutter is 110 and temperature of dough was 21 C̊.
CCPs in Biscuit Plant:
a) Dough temperature
b) Room temperature
c) Metal detector
d) Contamination of foreign material
e) Cutter arrangement
f) Knife sharpness

Calculate baking loss:
To calculate baking loss we weighed unbaked and baked weight of 10 biscuits.
Sr.# Unbaked weight Baked weight Baking loss %
(grams) (grams)
1 76.86 67.46 12.23 %
2 75.16 66.6 11.32%
3 74.4 63.73 14.38%
4 75.5 65 13.9 %
5 76.8 66.86 12.93%
6 79.6 67.76 14.8%
7 75 65 13.33%
8 75.76 65.3 13.80%
9 75.46 65.3 13.46%
10 79 68.26 13.59%
11 77.3 65.46 15.3%
12 73.86 63.9 13.48%
13 78.53 67.63 13.8%
14 75.13 64.16 14.60%
15 75.73 64.7 14.56%
16 76.2 65.1 14.56%
17 77.33 65.23 15.64%
18 75.2 64.4 14.36%
19 75.80 64.66 14.69%
20 78.13 66.6 14.75%
21 78 67 14.10%
22 76 65 14.47%
23 73.13 62.63 14.36%
24 79.53 66.4 16.51%
25 75.76 64.53 14.83%

Formula
Baking loss % = weight before baking – weight after baking x 100 / weight before baking
Result: Average baking loss is 14.15 %.
ASSIGNMENT # 5
Contents:
• Calculate biscuit being produce at cutter and packed at packaging machines.
• Calculate difference being waste
• Calculate rate of production per hour
• Plant capacity for 11 hours shift
• Calculate actual floor waste and rework with total wastage percentage
• Find machine stoppage reasons , wastage of wrapper and stoppage time
BISCUIT BEING PRODUCED AT CUTTER

CPM = 110
No of rows = 17
Biscuits produced in one minute = 110 X 17 = 1870 biscuits
Biscuits produced in one hour = 1870 X 60 = 112200 biscuits
BISCUIT BEING PACKED AT MACHINES
Speed of machines of H/R = 155
Biscuits in one packet = 10
Biscuits packed in one minute = 155 X10 = 1550 biscuits
Biscuits packed in one hour = 1550 X 60 = 93000 biscuits
Speed of machine of T/P = 100
Biscuits in one packet =3
Biscuits packed in one hour= 3 X 100 X 60 =18000 biscuits
Total packed biscuits = 93000 + 18000 = 111000 biscuits
WASTAGE PERCENTAGE
Production = 112200 biscuits
Packed biscuits= 111000

Wasted = 112200 – 111000 = 1200 biscuits
Wastage percentage = 1200 X 100 /112200 = 1.06 %
RATE OF PRODUCTION
Biscuits in one ctn = 10 X 6 X 24 = 1440 biscuits
Production in one hour = 111000 /1440 = 77.08 carton / hour
PLANT CAPACITY FOR 11 HOURS SHIFT
Maximum cutter speed = 170 CPM
No of rows = 17
Biscuits in one hour = 17 X 170 X 60 = 173400 biscuits
Biscuits in 11 hour = 172400 X 11 = 1907400 biscuits
H/R ctn in 11 hours = 1907400 / 1550 = 1230 ctn / shift
FLOOR WASTE AND REWORK WASTE FROM 8:00 AM TO 2:30 PM

Sr # Wastage type Floor Rework
1 Wastage at cutting 3.4 kg N.A
2 Packaging waste 335 g 600 g
3 Stacker wastage 783 g 36.69 kg
4 Wastage by QA 35 g N.A
5 Machine wastage 100 g 4 kg
6 Wastage due to dough problem N. A N.A
7 Wastage at oven section 20 g 5.060 kg
8 Wastage due to product mishandling N.A N.A
9 Wastage at stacker belt end 4.450 kg 80.38 kg
Total 9.123 kg 126.73 kg
Total production = 2575.584 kg

Wastage = 9.123 + 126.73 = 135.853 kg
Wastage percentage = 135.853 X 100 / 2575.584 = 5.27 %

MACHINE STOPPAGE REASONS:
1. Camera out
2. Panel out
3. Stamp problem
4. Slow labor
5. Magazine / feeding problem
6. Reel change
7. Over heat / low heat of sealers
8. Gap in processing
WRAPPER WASTAGE
Total packets packed in one hour = 120 X 60 = 7680
Total wasted packets = 39
Wastage percentage = 39 X 100 / 7680 = 0.507 %
STOPPAGE IN ONE HOUR
Working time = 60 mints
Stoppage = 7 mints
Stoppage percentage = 7 X 100 / 60 = 11.66 %
ASSIGNMENT# 6
Contents:
• Calculate batch consumption time
• Calculate number of biscuits per batch
• Ctn / batch
• If we support to operate plant at 400 CPM then how many packaging machines are
required if the speed of machines in 100
Batch consumption time is 19.40 minutes

Mixer emptying time = 1:06 mints
Trolly moving and loading time = 0:29 mints
Time on conveying belt = 20 seconds

Time from mould to oven = 30 seonds
Baking time = 2:24 mints
Cooling time = 4:53 mints
No of biscuits per batch:

CPM = 230
No of rows = 25
Biscuits in one batch = 230 X 25 X 19.40 = 111550 biscuits
Ctn / Batch:
Biscuits in one ctn = 12 X 24 X 18 = 5184 biscuits
Ctn production per batch = 111550/5184 = 21.51 ctns
If we support to operate plant at 400 CPM then how many packaging machines are
required if the speed of machines in 100
CPM = 400
Rows = 25
Production in one mint = 400 X 25 = 10000 biscuits / mint
Biscuits packed by one machine = 100 X 12 = 1200/ mint

No of machines = 10000 / 1200 = 8.33 machines
8 machines will work at 100 speed and one machine will work at 33 speed to pack production
at 400 CPM at assumed zero wastage.

ASSIGNMENT # 7
Contents:
• Find baking loss for jumboo
• Behavior of product in different zones of oven
• No of burners in zones and color of flame in zones
• Count number of burners during standby mode and working mode on biscuit line no 5
BAKING LOSS FOR JAMBOO
Sr no. Unbaked weight of 4 pcs Baked weight of 4 pcs
1 9.7 grams 8.31 grams
Average 9.8 grams 8.33 grams
Average weight before baking = 9.8 grams
Average weight after baking = 8.33 grams
Baking loss percentage = 9.8 – 8.33 X 100 / 9.8 = 15 %
Zone behavior and no of burners

Sr Type Temperature Burners Flame Product behavior
no color
Adjusted Working
1 Direct 102 C̊/98 C̊ 86 C̊/90 C̊ 20 Blue Puffing
2 Indirect 165 C̊ 172 C̊ 1 Yellow Puffing
3 Indirect 215 C̊ 228 C̊ 1 Yellow Puffing and baking
4 Indirect 211 C̊ 211 C̊ 1 Yellow Baking
5 Indirect 215 C̊ 212 C̊ 1 Yellow Baking
6 Indirect 214 C̊ 204 C̊ 1 Yellow Baking and coloring

Number of burners during standby mode and working mode on biscuit line no 5
Zone Actual Burners Temperature Burners Temperature
no. burners STB (C̊) STB W (C̊) W
Top Bottom Top Bottom Top bottom Top Bottom Top Bottom
1 9 10 6 6 122 142 6 9 138 146
2 11 13 10 13 193 145 10 13 187 146
3 8 12 6 10 185 150 6 10 198 145
4 8 8 7 6 198 134 7 6 175 137
5 8 7 6 4 206 123 6 4 185 133
6 8 7 8 0 189 100 8 7 190 110
7 8 8 0 0 150 112 5 6 155 120
*STB= standby mode W= working mode
ASSIGNMENT # 8
Contents:
• Ingredients of wafer sheet and cream and make a batch
• Problems in wafer sheet due to mixing problems
• Make twelve parts of a plain sheet and find difference in different parts of sheet.
• Make twelve parts of tree laired cream sheet and find cream ratio in different parts of
sheet
INGRIDIENTS AND BATCH MAKING.

Ingredients for wafer sheet and batch mixing procedure
• Starch
• Flour
• Water
• Soda
• Salt
• Lecithin

• Corn oil
In mixer added water. Then added soda, salt and lecithin. Added flour gradually
and mixed it for 8 minutes and shifted to storage tank
Ingredients for wafer cram and batch mixing procedure

• Fat
• Sugar
• Color
• Flavor
• SMP powder
• Whey powder
• Starch
• Glucose / Dextrose
Added fat in mixer. Then added SMP powder, whey powder 6 kg sugar, glucose and
starch.
Added color flavor and grinded sugar. Mixed till holes formation in cream
PROBLEMS IN WAFER SHEET DUE TO MIXING CORRECTIVE ACTION

 Water and lecithin are not measured properly that cause thick and thin problem in
wafer sheet.
 Underdeveloped and overdeveloped are dependent of mixing time that cause problem
in wafer sheet,
 If batter is overdeveloped then more gluten will develop that cause chipping of sheet.
 If batter in underdeveloped then the corner of sheet will not be formed.
 If sheet weight is less then less water is used about 5 liters less.
 If sheet weight is more, then more water is added.
 If sheet is soft then we use less soda, if sheet is hard then more soda is added.
 If sheet is hard then more corn oil is used.
 If sheet is being separate after baking then amount of soda is reduced.
 If sheet is soft then more salt is added to strengthen the gluten network.

 If sheet is sticking with oven plate then more lecithin is added
MAKE TEWELVE PARTS OF A PLAIN SHEET AND FIND DIFFERENCE IN

DIFFERENT PARTS OF SHEET.
There are 65 plates of oven so we took one reading of each plate by making 12 parts of each
sheet as mentioned above. All the readings are in grams.
Plate Part Part Part Part Part Part Part Part Part Part Part Part
no. 1 2 3 4 5 6 7 8 9 10 11 12
1 2.6 2.5 2.4 2.9 2.6 2.6 2.5 3.1 2.6 2.4 2.6 2.8
2 2.5 2.4 2.4 2.6 2.3 2.2 2.2 2.4 2.6 2.4 2.5 2.6
3 2.6 2.5 2.4 2.5 2.4 2.3 2.4 2.5 2.5 2.5 2.6 2.6
4 2.6 2.5 2.6 2.7 2.8 2.3 2.3 2.5 2.8 2.4 2.4 2.7

5 2.1 2.3 2.2 2.4 2.2 2 2.2 2.2 2.2 2.1 2.2 2.3
6 2.1 2.1 2.3 2.4 2 2.1 2.2 2.3 2.2 2.1 2.1 2.3
7 2.6 2.5 2.7 2.9 2.6 2.2 2.3 2.6 2.2 2.4 2.5 2.5
8 2.2 2.1 2 2.3 2.1 2 2.1 2.1 2.6 2.1 2.1 2.2
9 2.2 2.2 2.1 2.1 2.2 2.4 2.1 2.1 2.2 2.1 2.1 2.3
10 2.2 2.3 2.2 2.2 2 2.1 2.3 2.1 2.1 2.1 2 2.2
11 2.2 2.3 2.2 2.3 2.2 2.4 2.1 2.2 2.3 2.4 2.4 2.3
12 2.1 2.2 2.4 2.5 2.1 2.2 2.3 2.5 2.4 2.2 2.2 2.5
13 2.2 2.1 2.2 2.2 2.2 2.1 2.2 2.3 2.6 2.1 2.2 2.3
14 2.7 2.7 2.8 3 2.8 2.9 2.8 2.7 2.6 2.5 2.6 2.9
15 2.2 2.1 2.1 2.3 2.4 2.4 2.3 2.4 2.5 2.3 2.3 2.2
16 2.1 2.1 2.2 2.5 2.2 2.2 2.3 2.5 2.3 2.2 2.3 2.5
17 2.1 2.2 2.3 2.4 2.1 2.3 2.2 2.5 2.2 2.1 2.2 2.4
18 2.4 2.2 2.3 2.4 2.2 2.2 2.4 2.2 2.5 2.1 2.2 2.5
19 2.5 2.3 2.4 2.5 2.2 2.2 2.2 2.4 2.4 2.1 2.4 2.7
20 2.5 2.5 2.8 3.1 2.3 2.5 2.6 2.8 2.5 2.4 2.5 3
21 2.6 2.4 2.7 2.6 2.4 2.4 2.4 2.1 2.7 2.2 2.5 2.4
22 2.2 2.2 2.3 2.4 2.1 2.2 2.3 2.4 2.3 2.2 2.2 2.4
23 2.2 2.2 2.3 2.4 2.2 2.2 2.2 2.3 2.1 2.2 2 2.3
24 2.4 2.2 2.2 2.5 2.2 2.2 2.1 3.3 2.3 2.2 2.2 2.5
25 2.2 2.1 2.1 2.4 2.3 2.3 2.2 3.3 2.2 2.3 2.3 2.8
26 2.7 2.4 2.5 2.8 2.6 2.3 2.3 3.8 2.6 2.4 2.6 3
27 2.7 2.5 2.6 2.9 2.5 2.3 2.3 2.7 2.6 2.4 2.6 2.8
28 2.2 2.4 2.5 2.3 2.4 2.3 2.3 2.4 2.4 2.2 2.4 2.7
29 2.2 2 2.1 2.1 2.2 2.1 1.9 2 2.1 2.1 2.1 2.3
30 2.2 2.1 2.1 2.2 2.1 2.1 2.1 2.1 2.2 2.1 2.1 2.3
31 2.3 2.2 2.3 2.4 2.1 2.1 2.2 2.2 2.3 2.1 2.3 2.5
32 2.2 2 2.2 2.2 2.1 2 2.1 2 2.2 2.2 2.3 2.1
33 2.4 2.2 2.3 2.4 2.3 2.3 2.3 2.4 2.2 2.2 2.3 2.5

34 2.7 2.5 2.6 2.9 2.4 2.2 2.3 2.7 2.6 2.4 2.5 3
35 2.1 2.2 2.2 2.4 2.1 2.2 2.2 2.3 2.2 2.2 2.3 2.3
36 2.7 2.5 2.5 2.8 2.6 2.3 2.3 2.6 2.3 2.4 2.5 2.8
37 3 2.6 2.6 2.8 2.9 2.4 2.3 2.5 2.7 2.5 2.5 2.9
38 2.5 2.2 2.2 2.3 2.4 2.1 2.2 2.2 2.6 2.1 2.2 2.2
39 2.4 2.5 2.4 2.4 2.2 2 2.1 2.1 2.2 2.1 2.2 2.2
40 2.1 2.1 2.2 2.4 2.1 2.1 2.2 2.2 2.1 2.1 2.1 2.2
41 2.1 2.1 2.2 2.5 2.1 2.1 2.2 2.3 2.2 2 2 2.3
42 2.9 2.6 2.3 3.1 2.6 2.5 2.4 2.8 2.9 2.7 2.7 2.8
43 2.6 2.4 2.6 3 2.5 2.4 2.4 2.7 2.6 2.5 2.5 2.9
44 2.3 2.3 2.4 2.4 2.3 2.3 2.1 2.2 2.3 2.2 2.3 2.1
45 2.2 2.2 2.2 2.2 2.1 2 2 2.2 2.2 2.1 2.2 2.2
46 2.3 2.2 2.3 2.2 2.3 2 1.8 1.9 2.1 1.9 2 2
47 2.2 2.2 2.4 2.5 2.2 2.1 2.3 2.5 2.3 2.1 2.3 2.7
48 2.4 2.2 2.4 2.7 2.4 2.3 2.3 2.4 2.4 2.3 2.4 2.8
49 2.1 2.1 2 2.2 2.1 2 1.9 2 2.1 2.1 2.3 2.6
50 2.2 2 2.2 2.3 2 2 2.1 2.2 2.2 2.1 2.2 2.4
51 2.3 2.1 2 2 2.3 1.9 2.1 2.2 2.3 2.2 2.2 2.2
52 2.1 2.1 2.2 2.3 2 2.1 2.1 2.2 2.1 2.1 2.1 2.2
53 2.2 2.2 2.2 2.6 2.2 2.1 2 2.3 2.3 2.1 2.1 2.9
54 2.5 2.4 2.2 2.7 2.3 2.1 2 2.4 2.2 2.2 2.1 2.7
55 2.4 2.4 2.2 2.2 2.3 2.1 2.3 2.2 2.3 2.3 2.2 2.4
56 2.6 2.4 2.5 2.9 2.4 2.4 2.3 2.7 2.5 2.3 2.5 2.9
57 2.3 2.2 2.2 2.5 2.4 2.3 2.3 2.4 2.4 2.2 2.3 2.4
58 2.1 2 2.1 2.4 2.1 2.1 2.1 2.2 2.1 2 2.5 2.4
59 2.3 2.1 2.1 2.4 2.1 2.2 2.3 2.4 2.1 2 21 2.4
60 2.3 2.3 2.3 2.4 2.2 2.1 2.3 2.4 2.2 2.2 2.1 2.4
61 2.2 2.1 2.2 2.3 2.1 2 2.1 2.2 2.1 2 2.2 2.1
62 2.2 2.1 2.3 2.4 2.1 2.1 2.1 2.2 2.3 2.1 2.1 2.3

63 2.4 2.4 2.2 2.2 2.4 2.2 2.2 2.3 2.4 2.4 2.3 2.4
64 2.1 2.2 2.1 2.2 2.2 2.1 2.1 2.2 2.4 2.4 2.3 2.3
65 2.1 2.1 2.1 2.4 2.1 2.1 2.2 2.4 2.1 2.1 2.2 2.4
There was a difference in different parts of one plate and it ranged to maximum difference of
0.7-1.2 grams so mechanical department reviewed the depth / gap between every plate of
oven of plant no 3.
MAKE TEWELVE PARTS OF THREE LAIRED CREAM SHEET AND FIND

CREAM RATIO IN DIFFERENT PARTS OF SHEET.

Same sampling method was used for creamed sheet. We took ten readings to minimize error
in data. All the readings are in grams.
Sr# P1 P2 P3 P4 P5 P6 P7 P8 P9 P 10 P 11 P 12
1 21.3 27.1 26.1 22.8 19.9 24.9 24.4 21.3 22.5 24.8 23.8 22.6
2 21.7 27.6 27.5 24.7 24.4 28 27.1 23.7 23.2 29.5 27.8 25.3
3 21.5 27.3 28.1 24 22.6 29.2 29.8 26.9 22.3 27.5 26.9 25.1
4 24.5 30.2 28.9 25 24.1 28.2 27.3 24.3 25.6 29.1 26.7 23.8
5 19.4 23.8 21.8 17.4 24.4 25.5 22.7 20.7 23.3 24.5 22.2 18.9
6 20.8 25.1 25.2 21.4 21.3 26 25.9 22.9 23.8 26.1 23.8 22.5
7 19.1 26 25.2 20.9 21.9 26.1 25.5 21.8 22.7 28.4 26.5 21.3
8 22.1 25.3 24.5 21.1 25.2 28.8 27.9 24 26 27.1 27 23
9 20.9 28 28.1 23.5 18.5 25.7 26.4 22.4 21.5 27.4 25.8 21
10 19.2 24.4 24.4 22.2 19.6 24.2 23.5 21.7 23.8 28.9 27.1 23.3
*P1, P2, P3, P4, P5, P6, P7, P8, P9, P10, P11, P12 are parts of sheet according to cutting scheme.
Due to weight difference in different parts of sheet adjustments of cream machine were made
till the error was minimum.
ASSIGNMENT # 9
Contents:
• Find chocolate for one piece and no of pieces formed by one sheet.
• Find cream for one piece.
• Find plain figure weight.
• Weight of sheet, cream and chocolate for one carton.
CHOCOLATE FOR ONE PIECE AND NO OF PIECES BY ONE SHEET

Horizontal cut = 10
Vertical cut = 18
No of fingers formed by one sheet =10 X18 = 180 pieces
10 pieces weight before chocolate enrobing = 15.5 g

10 pieces weight after chocolate enrobing = 39.2 g
Chocolate consumed by 10 pieces = 23.7 g
Chocolate consumed by one piece = 2.37 g
CREAM FOR ONE PIECE

Weight of 3 plain sheet = 134.1 g
Weight of one finger = 134.1 / 180 = 0.745 g
Weight of 3 creamed sheet = 318.6 g
Weight of one creamed finger = 318.6 / 180 = 1.77 g
Cream consumed by one piece = 1.77 – 0.745 = 1.025 g
WEIGHT OF CHOCOLATE, CREAM AND SHEET FOR ONE CARTON

No of fingers in one carton = 36 X 36 = 1296
Cream for one piece = 1.025 g
Cream for one carton = 1.025 X 1296 = 1328.4 g = 1.3284 kg
Chocolate for one piece = 2.37 g = 0.00237 kg
Chocolate for one carton = 0.00237 X 1296 = 3.0715 kg
Weight of one uncreamed finger = 0.745 g
Weight of sheet for one carton = 0.745 X 1296 = 965.52 g
= 0.96552 kg
ASSIGNMENT # 10
Contents:
• Baking loss for wafer sheet
• Batch weight and total dry weight after baking of one batch
• Wastage and average carton per batch if one carton contain 0.96552 kg of sheet
• If one shift working time is 10.5 hours then how many batches are required and how
many carton are produced

BAKING LOSS
Container weight = 40 g
Batter weight of three sheets with container = 498.2 g
Batter weight without container = 498.2 – 40 = 458.2 g
Batter weight for one sheet = 458.2 / 3 = 152.7 g
Weight of one sheet after baking = 44.53 g
Baking loss = 152.7 – 44.53 X 100 / 152.7 = 70.8 %
TOTAL DRY WEIGHT OF BATCH

Weight of one batch = 65.5 kg
Baking loss = 70.8 X65.5 / 46.374 kg
Dry weight = 65.5 – 46.374 = 19.126 kg
WASTAGE AND AVERAGE CARTON PER BATCH IF CARTON CONTAIN 0.96552

KG OF SHEET
Actual production by one carton = 18 ctn
Calculated production = 19.126 / 0.96652 = 19.78 ctn
Weight of one carton (sheet) = 0.9655 kg
Packed weight of sheet = 0.9655 X 18 = 17.379 kg
Wastage = 19.126 – 17.379 = 1.747 kg
Wastage % = 1.747 X 100 / 19.126 = 9.1%
IF ONE SHIFT WORKING TIME IS 10.5 HOURS, HOW MANY BATCHES ARE
REQUIRED AND HOW MANY CARTONS ARE PRODUCED
Average sheets by one batch = 430 + 426 /2 = 428 sheets / batch
Batch consumption time = 19.53 mints
Shift working time = 10.5 hours = 630 mints
No of batches = 630 / 19.53 = 32.25 batches
No of sheets in one shift = 32.25 X 428 = 13803 sheets
No of sheets after creaming (3 plies) = 13803 = 4601 sheets (3 plies)

No of fingers production in one shift = 4601 X 180 = 828180 fingers
Fingers in one carton = 1296 finger
No of carton production in one shift = 828180 / 1296 = 639.02 carton / 10.5 hours shift
SUGGESTIONS / FEEDBACK:
General:
1) Products name and trademark logo should be unique and have no resemblance with
other as it has bad effect on consumer.
2) Resign ratio is high in industry and main reason for resign are duty hours, there should
be three shifts to reduce resigns.
3) Less co-operation between QA department and Production department
4) Height of cutting section in new hall should be reduced for better cooling.
5) Cutting section should be provided temperature gun instead of estimating temperature
with hand.
6) Quality inspector is controlling weight variation at cutting then he should be
responsible for weight variation throughout the process line
7) Quality Assurance inspectors should prefer online checking at packaging machine
instead of end carton.
8) Floors in mixing should be sanitized at least one time in a day.
9) Dustbins should be cleaned immediately when filled.
10) Emergency exit doors should not be locked.
11) There should be glue boxes at every outer door processing hall.
12) Every person in mixing should have health fitness certificate and have no
communicable disease.
13) There should be first aid training in industry every year.
14) There should be a medical service for any emergency.
15) Safety gloves and safety shoes should be provided to oven operators.
16) Mess should be improved and timetable should be maintained.

Wafer section:
1) There should be a hand drying facility with hand washing facility.
2) Temperature of mixing section is not controlled.
3) RPM of mixer at plant no.1 are less than other three mixers but mixing time is same
that should be calibrated.
4) Workers should wear mask during floor sieving.
5) Mixer should be cleaned after every batch instead of evening.
6) Temperature monitoring devices of oven are not calibrated for oven of plant no. 2,3
and 5 in wafer section.
7) Wafer cutting machines should be covered to avoid contamination.
8) Drinking of water should not allow in mixing and there should be a sign for not
drinking area.
9) Drinking water facility should be with hand washing facility in wafer section.
10) Lecithin should be measured accurately.
11) Filtration cloth should be used for filtration of batter to avoid spreading gun blockage.
12) After washing, floor should be sanitized at least one time in a day.
13) SMS should be added 1-2 minute before completing mixing instead to adding at the
start of mixing.
14) Water in wafer mixing section is not clean.
15) By managing labor or increasing labor we can increase production of wafer about 35
% at same equipment
Biscuits sections:
1) There should be hand washing facility in hew hall and chocos hall.
2) Windows should have auto closing mechanism for batter IPM.
3) Wrapper for packaging should not be stacked to floor in store.
4) All the doors (both parts of door) should have auto closing mechanism because doors
are opened for long period of time and workers should be trained to always keep doors
close. And there should be a sign on door showing that doors are auto closing.
5) Windows of old hall should be cleaned after a specific period.

6) Windows of new hall are opened that should not be opened.
7) There should be emergency light in chocos hall.
8) For belt stitching there should be a stitching machine as most of gaps are due to belt
stitching.
9) Cooling conveyer rollers may harm to workers as the packaging machines are beneath
cooling belt.
10) Cutter of packaging machines should be changed or repaired.
CONCLUSION:
Industry in working since 2004 and continuously growing. Now company has seven biscuit
plants and four wafer plants and one plant for chocolate coated wafer plant. No one in the
industry is allowed to visit mixing except mixing men and their supervisors. . Company is
ISO certified, Halal certified and Pakistan standards certified. Company is following HACCP
but not HACCP certified. Projects studied during the internship were highly interesting and
educative. The enthusiasm and interest shown by the office bearers and managers of industry,
during my internship helped me in understanding appropriately the functioning of this
Industry. This internship program has made me realize the value of working together as a
team and gave me a new experience in working in a social environment, which challenges our
mental and physical faculties every minute. This short time internship programme provided
to me an opportunity to work in different settings and exposed me to interaction with different
sets of people. The working environment the Industry was highly motivating and inspiring.
We worked in different departments of industry and in every department we worked with a
new set people. We worked in quality department and filled quality control and quality
assurance reports according to sample specifications. We also worked in production
department of old hall, new hall, wafer section and chocos hall. Quality assurance department
lacks the quality inspector so sometime cutting and oven section in monitored by one quality
inspector and he cannot fulfill his duties because if he is controlling weight variation at
cutting then he should be responsible for weight variation throughout the process line. Quality
Assurance inspectors should prefer online checking at packaging machine instead of end

carton. Production can be increased by managing labor by their training about GMPs of
industry.
References
[1] http://innovativebiscuits.com/
[2] Baking science and technology 4th Edition, E.J. PYLER AND L.A. GORTON
[3] Technology of biscuits, crackers and cookies, 3rd Edition, Duncan Manley
[4] http://www.marthastewart.com/265820/essential-baking-tools
[5] http://www.quakeroats.com/cooking-and-recipes/content/baking-101/welcome-to-baking-
101/baking-equipment.aspx

Internship Report Muhammad Arshad

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Internship Report Muhammad Arshad

Uploaded by

Copyright:

Available Formats

INNOVATIVE BISCUTS Pvt.

It is certified that no objectionable Submitted by: Muhammad Arshad

M.ARSHAD INTERNSHIP REPORT 1

INTRODUCTION AND HISTORY OF COMPANY

M.ARSHAD INTERNSHIP REPORT 2

BISCUITS BRANDS WITH THEIR PRODUCTS

M.ARSHAD INTERNSHIP REPORT 3

WAFERS BRAND WITH THEIR PRODUCTS

M.ARSHAD INTERNSHIP REPORT 4

• Orange cream wafers

M.ARSHAD INTERNSHIP REPORT 5

M.ARSHAD INTERNSHIP REPORT 6

M.ARSHAD INTERNSHIP REPORT 7

M.ARSHAD INTERNSHIP REPORT 8

M.ARSHAD INTERNSHIP REPORT 9

M.ARSHAD INTERNSHIP REPORT 10

 BISCUITS BAKING OVEN:

1. First zone raises the biscuit.

M.ARSHAD INTERNSHIP REPORT 11

M.ARSHAD INTERNSHIP REPORT 12

M.ARSHAD INTERNSHIP REPORT 13

Choc ‘n’ chip:

M.ARSHAD INTERNSHIP REPORT 14

M.ARSHAD INTERNSHIP REPORT 15

Flour is a very important ingredient which can impart unique appearance,

M.ARSHAD INTERNSHIP REPORT 16

Water is a basic ingredient in baking. It would be impossible to produce biscuits without

• It makes possible the formation of gluten.

M.ARSHAD INTERNSHIP REPORT 17

• Sodium bicarbonate: (NaHCO3)

M.ARSHAD INTERNSHIP REPORT 18

 SKIMMED MILK POWDER:

M.ARSHAD INTERNSHIP REPORT 19

M.ARSHAD INTERNSHIP REPORT 20

• Eggs contribute flavor to the product.

 SMS (SODIUM METABISUPHITE)

M.ARSHAD INTERNSHIP REPORT 21

Cooling Baking Rolling and shaping Mixing

Stacker Sorting & packing Storing Dispatch

PROCESSING LINE FOR BISCUITS

M.ARSHAD INTERNSHIP REPORT 22

The other raw materials are also stored properly.

• Scale all ingredients accurately.

• Combine the liquid ingredients.

M.ARSHAD INTERNSHIP REPORT 23

5. Metal detector (CCP):

6. Rolling and Shaping/ Cutting:

M.ARSHAD INTERNSHIP REPORT 24

M.ARSHAD INTERNSHIP REPORT 25

The function of stacker is that it makes arrangement of biscuits which facilitates in

In this step the following things are

M.ARSHAD INTERNSHIP REPORT 26

The finally packed product is stored in ware house or dispatch room.

Then the product is dispatched to market.

M.ARSHAD INTERNSHIP REPORT 27

M.ARSHAD INTERNSHIP REPORT 28

Cooling Baking Sheeting Mixing

Creaming Cutting & enrobing Packaging Dispatch

 PROCESSING LINE FOR WAFERS:

M.ARSHAD INTERNSHIP REPORT 29

Weighing & sifting:

• Scale all ingredients accurately.

• Add chilled water in the mixer.