Professional Documents
Culture Documents
Hossana, Ethiopia
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LIST OF TABLE
LIST OF FIGURE
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Figure 11. packaging machine......................................................................................................26
TABLE CONTENTS
LIST OF TABLE...........................................................................................................................1
LIST OF FIGURE.........................................................................................................................1
TABLE CONTENTS.....................................................................................................................2
DECLARATION...........................................................................................................................5
ACKNOULEDGMENT................................................................................................................6
EXECUTIVE SUMMARY...........................................................................................................7
CHAPTRE ONE............................................................................................................................8
1. Introduction...............................................................................................................................8
1.2. Vision....................................................................................................................................8
1.9. Objectives............................................................................................................................11
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1.9.2 Specific objectives.........................................................................................................11
CHAPTER TWO.......................................................................................................................13
2.3.2.3. Mixing....................................................................................................................20
2.3.2.3.2. Application......................................................................................................21
2.3.2.6. Molding..................................................................................................................23
2.3.2.11. Packing................................................................................................................32
CHAPTER THREE.....................................................................................................................37
CHAPTER FOUR.......................................................................................................................41
4.1. Conclusion..........................................................................................................................41
4.2. Recommendation................................................................................................................42
REFERENCS.................................................................................................................................43
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DECLARATION
I would like to declare that, I would successfully complete four months of my internship
program at the company called Eshet food complex. I have worked at Eshet food complex in
the given four months successfully. In addition I declare that all written in this document are
performed by my effort and with the help of my monitor Mrs. Melkayo.
Thus, I want to certify for the above statement and for the successful completed
internship program.
Sign
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ACKNOULEDGMENT
First, I would like to thanks the almighty God for his give me the strength and wisdom to
successfully complete the company work and this final report. Moreover, I would like to
express my heartfelt appreciation thanks to my advisor Mrs Melkayo and Mr. Ermiyas for
their appreciable guidance, advising, for sharing their knowledge, skills experience and fine-
tuning up to successful completion of worked time and report writing time. And also I would
like to acknowledge my classmates who helped me during my document writing. Finally I
would like to acknowledge my family with the deepest gratitude that encouraged me to strive
towards academic excellence and always wish the best for them.
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EXECUTIVE SUMMARY
This report is focused on the production of Biscuit. Biscuits are produced from flour and other
ingredient. Eshet food complex company is produced flour and biscuit for market. I was able to
participate on biscuits production process. Biscuit is a popular food product where it was
produced using wheat flour, sugar and fat as its main ingredients. Wheat flour was the major
material used in biscuit production and within the flour starch is the principal component. Major
ingredients are water, flour, sugar. Minor ingredients are fat, sodium bicarbonate, ammonium
bicarbonate. Starch is the major structural element in many foods, with the fat or sugar also
playing key roles. Sugar gives sweetness, color, add volumes and influence the texture of a
biscuit. Besides that, it shows significant impact on starch gelatinization properties. Fat plays an
important role in biscuit production and the type of fat used determines the quality of the final
product. This internship helped me to get better in different areas of work related issue. I was
working as a food scientist in order to improve most of my skills like, communicative skill,
theoretical skill, practical skill, ethics of the work and others.
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CHAPTRE ONE
1. Introduction
1.1. Background of the Organization
Eshet Food Complex (EFC) is a private owned factory established in October 2004
E.C following the previously planted Flour factory in the vicinity which proved to be
successful. The Eshet food complex (EFC) is placed in Shashemene City
Administration.
In a short time after its establishment, it started producing high quality flour and a
variety of biscuits with a common brand "Eshet" its products are widely available in
every market around most of the Oromia regions. The region where our factories reside
is 175 Km away from the city capital, Addis Ababa; Oromia region is famous for
growing high quality wheat with most quantity nationally. The factory is capable of
producing various kinds of biscuits and flour to the local as well as the international
market; currently they are producing flour and biscuit.
Currently the company has totally 220 workers. Workers by the amount of 150 are
permanent and the rest of 70 are leased.
Source; from interview
1.2. Vision
Company vision is to be a lucrative company specialized in producing an international
quality Biscuits that supply to the local as well as the international market. They also
need to produce high quality, quantity and long shelf life of products.
Eshet food complex have another strong vision, to satisfy the demand for food in
Ethiopia and work hard to produces best biscuits.
1.3. Mission of the Organization
Eshet food complex is strongly committed to produce and provide safe nutritious and
high quality biscuit products that fulfill applicable international, national and mutually
agreed food safety and quality standards regulatory and statutory requirement to
highest satisfaction of its custom.
Eshet food complex have strong vision, to deliver high quality biscuits and flour
supplies to their customers.
The administration: Whose job is to control the operation of a plant in man power management,
row materials management and manage working hours of the plant.
The finance: Whose job is purchasing all the row materials needed for the biscuits production
and controlling the amount of row materials which will be brought by the company in order to
protect extravagance.
The production and techniques: works on each unit operations individually and by mass
controlling and operating the machines.
1.9. Objectives
Product
ion
departme Quality
Technical
nt departm
departmen
ent
t
Finance Production
administrat supervisor
ion
Eshet Laborator
General
food y
Manager
complex
Human Chemist
resource departm
manageme ent
nt
Marketing
Security departme
Cafeteri nt
a
Challenges
Since, it was my first time to be in a working environment, I had faced different challenges
during this internship period. In Eshet food complex company there were five students entered
for their internship program, from those, I was one of them. Without me the rest four of them
were know Afan Oromo and the company manager could not communicated by Amharic and
only communicated by afan Oromo. This great challenge was faced for me at the first time.
The second great challenge was the working time of the company. The company works was
achieved by shift and the morning shift was from 12Am to 8Am and the afternoon shift was from
8Am to 4Pm. So, the company manager said us, we must work together with the worker as a
company rule and regulations as the time set by the company. This was another big challenge for
me. Another challenges was, there is no professional person, who could help us on our questions.
Measures taken
To communicated with the company manager, I gone to him with friends who know afan
Oromo. We solved the challenges of working time by discussed with them and they modified the
working time only for us, for shift A (morning) 2Am to 8Am and for shift B (afternoon) 8Am to
12Pm.We get some answers about our questions from some professionals like mechanics and
food engineers. I searched Google to get more information about biscuit production.
B. Soft dough contain much less water and relatively high level of fat and sugar .the
dough is short, (it breaks when it is pulled out) which means that exhibits very low
extensible character. Short dough’s, which are soft enough to be just pourable, are
called as soft dough.
Pieces are formed by extrusion in a similar way and in the same machine as wire cut
and rout biscuits but nozzles rather die holes are used to channel the dough. The dough
is reseed pressed out either continuously or intermittently on the oven band that may be
raised up and then dropped if discrete deposits are requires. As the band drops, the
dough pieces break away from the nozzle. The biscuits produced in this way are
usually rich in fat or based on egg whites whipped to a stable form, the dough must be
very short to allow it to break away easily as it is pulled away from the nozzle.
2.3.2. Biscuit Production Steps
Biscuit are flour based that are generally crisp and crumbly in texture, due to fact that
they baked twice. The name "biscuit "comes from French word which means "twice
cooked "during the production of biscuit workers follows some step which is the same
very where. Some steps are common they are:
moulded
Baked
Cooled
The structure and texture of the biscuit was determined by the ingredients, mixing and forming
and the baking process. Here we would introduce briefly the main ingredients and process
requirements for the baking of biscuits. Our aim was to indicate the complex chemical and
physical changes which take place with temperature and particularly during baking. This would
inform how we designend and operated the baking oven.
Wheat flour
The principle ingredient of biscuits was wheat flour. The grain consists of bran (12%), which
was the outer husk, endosperm, which were the white part (85.5%) and the tiny germ (2.5%).
Typical biscuit flour was milled to a yield or extraction of 70-75%. Whole meal flour is of 100%
extraction and wheat meal flours in between these extraction rates, normally around 84%
extraction. The flour would also contain moisture of between 13 – 15%.The wheat flour is
composed of carbohydrate (as starch), protein and fat, together with some fiber, ash and trace
minerals and vitamins. The protein is mainly gluten, composed of gliadin and glutenin. The
percentage of protein determines the flour strength. Dough made from strong flour with high
protein content, is extensible and can be machined into a continuous sheet for crackers and hard
biscuits. Weak flour with low protein content produces soft dough which may be molded or
deposited on the baking band and when baked, gives a short texture. ( Lui, Q. 2005.)
Sugar
Source of carbohydrate
Common sugar (sucrose) is a carbohydrate derived from sugar cane or sugar beet. Sucrose is a
disaccharides composed of two monosaccharides, A molecule of glucose joined to a molecule of
fructose. Sugar gives sweetness, but it is also important in developing the texture of the biscuit.
Dissolved sugar tends to inhibit starch gelatinization and gluten formation and creates a biscuit
with a more tender texture. Undissolved sugar crystals give a crunchy, crisp texture. Sugar
crystals, which melt during baking, cool to a non-crystalline glass-like state which gives a crispy,
crunchy texture, particularly on sugar topped biscuits
Dry sucrose melts at 160°C – 186°C. Biscuits with sugar toppings which are melted to a smooth,
shiny surface require high intensity flash heat at the end of the oven to fully melt the
Sugar is most commonly thought of as a sweetener, but in baked goods it is also involved in
several other processes. Sugar undergoes a series of complex browning reactions above 160oc,
and the products of these form the brown crust of many baked goods. The reactions are known as
Millard reactions, and are essentially amino acid-catalyzed Caramelization reactions in which a
sugar aldhyde or ketone is converted to unsaturated aldhyde or ketone.
Invert sugar syrup is a mixture of glucose and fructose. The sucrose is split into its component
monosaccharides by hydrolysis. The sucrose in solution is heated with a small quantity of acid
such as citric acid. After inversion, the solution is neutralized by the addition of soda. The invert
syrup is sweeter than sugar and it contributes to moist, tender texture in the biscuit.
Shortening
Vegetable fats
Fats are a vitally important ingredient in achieving the texture, mouth feel, and the bite of the
biscuit. The fats are produced from good quality crude oils by a process of refining, bleaching
and deodorizing. They are produced primarily from vegetable oils, but may contain
hydrogenated fish oils. Typical blended vegetable dough fats are solid at ambient temperature
and melt over a wide temperature range. Most fats used in biscuit making are melted below
blood temperature (36.9oC), and this avoids a waxy mouth feel.
Provide an elasticity property to the dough during mixing then side effect of SMS is loss of
memories.
Lecithin
Works as an emulsifying agent, in which it mixes the fat with water and other ingredients.
Glucose syrup
Glucose syrup (C6H12O6) is a solution (up to 80%) of glucose (dextrose), maltose and malto
dextrin in water. It is normally obtained by enzymatic hydrolysis of starch. Starch from wheat,
corn, potato, cassava or any other plant can be used for this purpose. Standard glucose syrup has
a DE value (dextrose equivalent) of 42.
Additives
Natural color
During mixing process of ingredients, some permitted additives of color are added to change the
color of dough like: Orange color, Chocolate color and Vanilla color
Natural Flavors
At the same condition flavors is one of the most requirements during preparation of dough for
biscuit and during the preparation of cream. These ingredients determine the type of biscuit that
is produce. For cream formation many kinds of flavors are used. Some of them are the
following:- Cappuccino flavor ,Apple flavor, Orange flavor, Apple flavor and Vanilla flavor
Leaving Agents
For the production of biscuit most biscuit makers use leaving agent instead of yeast for dough
treatments. Ammonium bicarbonate used as foaming agent of dough and sodium bicarbonate
used to kill some microorganisms and to stop growing of some bacteria.
Yeast is normally used in the production of cream crackers. The yeast is most active at
temperatures of 30°C – 35°C during dough fermentation. At temperature above 40°C, the yeast
activity stops and is there for inactive during the baking process.
Soda is readily soluble and it reacts with acidulates in the dough in the presence of water,
producing carbon dioxide and decomposing to salt and water. The speed of the reaction may be
controlled by the type of acidulate used. The leavening of the dough takes place during mixing
and fermentation of the dough
Ammonium bicarbonate
This leavening agent decomposes completely when heated, producing carbon dioxide, ammonia
and water. The reaction is rapid at around 60°C and therefore the expansion of the dough takes
place during the initial stages of baking. Used in food industry as raising agent and completely
decompose in to gaseous products that evaporate during baking. But it cannot be used for most
bulky baked goods however, such as normal bread of cakes since some ammonia will be trapped
inside and will cause unpleasant taste. Decompose above about 360C in to ammonia, carbon
dioxide, and water in an endothermic process and so cause a drop in the temperature of the
water. Sodium bicarbonate has the property of releasing CO2 when it is heated:
Water
Water is very important material for the formation of dough and for all cleaning process at any
time. Cold water is used during the preparation of dough.
Water is an essential ingredient in dough which when added to wheat flour helps in the
formation of gluten by hydrating the gluten proteins when dough is subjected to mechanical
mixing. The gluten provides to the dough its characteristic rheological properties like desired
strength, extensibility, gas retention power and elasticity. The water has additional functions as
follows: first it helps in maintenance of a particular temperature of dough during mixing. Then
Amount of water determines the consistency of dough. Then it helps in the distribution of
dissolved salt and sugar uniformly throughout the dough and it facilitates the activities of
enzymes in dough. Finally Water helps in the gelatinization of starch during baking.
2.3.2.3. Mixing
Mixing of the ingredients was an action at which all the required ingredients are mixed
together in a proper amount and type.
Mixing was done in the two stages. In the first stage, all the ingredients mixed except
the flour. For the second stage, the flour was added and mixed for 1 minute at slow
speed and 1-2 minute at high speed. The final dough temperature should be 18-220c.
2.3.2.3.2. Application
Dough Mixer – The dough mixer is utilized for the mixing of various ingredients used
in the production of biscuits. These ingredients include flour, fat, sugar, water and
other chemicals used in forming soft, hard or fermented dough that was then used to
make the cookies and biscuits. Inside the mixing chamber, there are typically one
mixing blades that are fitted which rotate in continually at varying speeds. This process
allows the dough mixer to mix different types of hard or soft dough, thereby achieving
the right dough consistency. The dough mixer was covered on all sides to prevent the
occurrence of accidents as well as the penetration of dust. The capacity of the dough
mixers were 100kg.flour, 200kg.flour, 300kg.flour per batch.
2.3.2.6. Molding
This stage was a stage at which the mixed dough was formed to be sheet, shape and cut
at this stage well-mixed dough was molded. There were two type of dough are found,
hard and soft dough. Baking was a step at which the molded (shaped dough) pass
through the oven.
2.3.2.7. Baking
The biscuit move on to a flat steel band wire mesh conveyor that would carry them
through the oven in a continuous process. They were passed through a funnel oven and
baked as they move. The first requirement in baking was aeration of the mixture by
incorporation of gas. The second was coagulation of the material by heating in the
oven. So that the gas was retained and the structural of the material was stabilized.
Parts of oven
A. Sensor
This determines temperature of each zone in the oven, and display on the control panel
board.
B. Flap
A handle found on each zone, used to close & open or partially open the metal pipes as
desired for the flow of hot air.
C. Metal pipe
The compressed hot air flows through a high heat resistant stainless steel pipe.
D. Wire mesh
It was long mesh metal conveyor belt which can resist high temperature. It passes
through the oven carrying the dough at the inlet & baked biscuit at the out let.
E. Control panel board
It displays all the parameter & conditions like temperature and air pressure, speed of
wire mesh.
f. Steam pump piece:
Each house (zone) has fan which pumps steam from dough to the atmosphere through
steam pipe.
Moisture zone: - at this step moister was removed. -gas delivery or evaporation
takes placed, example Ammonia
Baking zone:
Coloring zone
A second browning process, dextrinisation was the breaking down of starch molecules
by heating. This produces pyrodextrins which were brown in color and have a
distinctive flavor. Dextrinisation of the starch occurs at temperatures of 100-200°C.
The third browning process is known as the Millard reaction. This was a complex
chemistry in which many compounds are formed at high temperatures by the reaction
of reducing sugars and amino acids. Since milk has a high content of proteins and
amino acids, the Millard reaction would also contribute to the color of biscuits which
have been brushed with milk before baking giving a darker rich brown color.
These browning processes all require high temperatures and occur when the biscuit
surface was already dry. The coloring takes place in the final stage of the baking
process. Majority of moisture removed during Stages 1 & 2 and coloring now
occurs .Structure was fully set and Product was firm, The color develops due to: –
Sugar Caramelization – protein reactions
(Millard browning) These also develop flavor
2.3.2.11. Packing
During packing a number of biscuit pass (pushed) by stick on the machine and warped
by plastic cover and this cover attached by high temperature.
There were two types of packaging. Primary packaging and Secondary packaging
(carton sealing)
Storage was the final phase of biscuit and cookie production that in evolves storing product in
containers, facilities and conditions that was guaranteed to maintain the shelf of the product.
2.3.3. Quality control and assurance
Diameter of biscuits was determined by placing four biscuit samples edge to edge and
measuring with a digital vernier caliper. An average of six values was taken for each
set of samples. Average value for diameter was reported in millimeter. Weight of
biscuits was measured as average values of six individual biscuits with the help of an
analytical weighing balance. Average value for weight was reported in grams. Spread
ratio was calculated by dividing diameter by thickness. Spread ratio or diameter is used
to determine the quality of flour used in preparing biscuits and the ability of the biscuit
to rise.
Textural quality [hardness and fracturability] was a very important and desirable
quality attribute for biscuit. Hardness, which was the peak force required to break the
biscuit, decreased as the percentage inclusion of PPF in the formulation reduced.
Fracturability measures the ability of a product to fight to regain its original status or
form. Fracturability of the biscuit samples significantly (p < 0.05) reduced as the level
of UBF increased. Apart from the baking conditions, the type, quantity of ingredients,
and protein content of the flour used have been reported to influence its hardness and
other textural attributes
Crispness of biscuits
Crispness of biscuits was one of the most important for customer. The interaction of
cultivar and growing environment significantly influence the crispness of biscuit
production. The result indicated that the dry matter content of cultivars influence the
crispness of the biscuit.
I know to handle material and equipment in order to maintain the quality of product,
process unit operations involved in biscuits production.
Honesty: honesty at work means spending working hours and resources totally on
work. as l have observed in the company all the labors spend their time on work but
they have a break time to talk with their friends over coffee and tea. They wear
working clothes on the work, not outside the work place. They also use transportation
services only from the company labor.
Initiative: this means being prepared to see what needs doing and to do work without
always being asked or told to do it. When you finish a piece of work and see something
else that needs doing, you have to take the initiative to do that work. As we have
observed in the company some of the labor do their work without command by other
person I have also tried to participate to help all workers in all section of the process.
Loyalty: it is important always to support your employer and do what is best for the
growth of the organization.
Maximizing productivity: this is the ability to do high quality work faster and
efficiently. Some workers produce good quality but they are slew. Others work quickly
but the quality was low.
Willingness to learn: this means understanding the way things are done at your work
place and trying to do it better.
Practical activity is exactly corresponding to the theoretical lesson that I have learned
in the previous three years course and reference material that I got a chance to refer.
During my internship period in Eshet food complex, I upgraded my theoretical
knowledge, which I have been learned in the previous three years. My theoretical
knowledge got strengthen more by those practical techniques. This is because I had to
refer Every time when I came across a problem.
Going through a report that was on a bid evaluation, I learnt the basic requirements of a bid
evaluation. Depending on the results of technical evaluation, the financial proposal of the bidder
will be opened in the presence of the bidders, consultants, and the clients or their representatives.
a team of bid evaluating committee will take over the document and evaluate it. What is
expected from the financial offer and technical proposal will be stipulated in the bidding
document. after the financial and technical score are presented the combination of the two is
presented. a bidders achieving the highest combined technical and financial score would be the
winner. the committee will finally reveal their recommendations based on the evaluation they
made. the contractor whom may then accept their judgment or discuss with the advisor who
chooses.
Every activity excited in a month will compiled in document called monthly report. this
document will contain the contract condition and name of the clients, work executed in that
month, the work schedule, problem encountered, supervision report, tests conducted, number of
employer, equipment used, photo report, total work executed, and at the end summary for the
month.
CHAPTER FOUR
4.2. Recommendation
What I recommended is such thing that may be helps the company as my idea in case
of safety this company produced food so all workers contact to biscuit must wear hand
gloves and cover their hair.
The company employers most of them works by experience so it is good if employee
more professional person in every important areas.
The company must reduce scrap biscuit in every unit operation area by ordering
employers each and every unit operation area.
Since eshet food complex (EFC) factory production machines were modern and it's
producing product were very well but, they couldn't how to protect it's modernity.
They should need skilled mechanics.
The factory should assign professionals and skilled workers for specific duties.
They should receive enough amounts of raw material (wheat) for their current and
future production.
They should advertise their products for the people in order to get market
acceptance.
The factory should allocate budget for the buying of generator which reduce all the
losses which caused by lack of electricity.
Most low level workers have no enough knowledge about some ingredient they
used, to solve this problem they should give different tutorials and give the chance
to improve their background knowledge but not based only on experience
Also your products are for local market, please extend to foreign country
The company should work on quality more to strengthen its relationship with
customers.
The company should employ additional well experienced workers.
Written documents and releasing information to the website to the internet are
needed.
The company should have additional working clothes as a reserve
Lack of Greenness of compound. Also, the laboratories are not fully organized I
think the top management is not focused and I recommended that the company
must fulfill the necessarily laboratory equipment in order to produce high quality.
REFERENCS
Atwell, W. A., Hood, L. F., Lineback, D. R., Varrianomarston, E. and Zobel, H. F.
1988. The technology and methodology associated with basic starch phenomena.
Cereal food world 33: 306-311.
Lui, Q. 2005. Understanding starch and their role in foods. In steve W. C. (ed). Food
carbohydrates: chemistry, physical properties, and application, P. 310-355. Boca
Raton: CRC press.
Iain Davidson (2016), biscuit baking technology 2nd edition processing and engineering
manual pp. 35-48 and pp. 73-91.
Manley, D. 2000. Technology of biscuit, crackers and cookies. Cambridge: woodhead publishing
limited.