About Rudrapur Plant

           Total plot area 440 X 180 = 79200 sq m. Production trail started on 1st April 2005. TIGER product approved on 15th April 2005. GOOD DAY approved on 20th May 2005. 50-50 approved on 19th October 2005. Unit recommended for ISO22000 on 24th March 2006. Cream plant commenced with ORANGE TREAT followed by Bournbon in July 2006. SQC/SPC implemented for the first time on 50-50 line from October 2006. GOOD DAY pile pack production started on December 2006. Commercial production of MASKA CHASKA by the end of 2006. TQM initiative started in the GOOD DAY line from February 2007.

Total production of company is 7000 tons per month. Biscuits manufactured in this Rudrapur plant are1. Good Day Butter 2. Good Day cashew 3. Good Day Pista Badam 4. 50-50 5. Maska Chaska 6. Pure magic vanilla and Pure Magic Chocolate. 7. Milk Bikies milk cream. 8. Bourbon 9. Orange Treat-O 10. Time Pass Ingredients and their storage 1. Flour- Refined wheat flour 2. Fats/Oil a. Refined Palm Oil. b. Palmolin Oil 3. Sweetening Agent a. Crustal Sugar b. Liquid glucose 4. Dairy food a. Butter b. Skimmed milk powder c. Condensed milk 5. Yeast- compressed yeast 6. Enzymes a. Papain b. Neutrase c. Dopeh Enzyme d. Fungamyl 8001 7. Colors a. Ponceau b. Tartrzine

Flavors a. Ethyl vanillin b. Butter flavor c. Cocoa powder d. Black jack 9. Emulsifier a. Lecithin b. GMS c. Solbake 10. Antioxidant a. TBHQ b. BHA 11. Aerating Agent a. Ammonium bicarbonate b. Sodium bicarbonate 12. Chemicals a. NaCl b. Citric Acid c. Lactic Acid d. SMBS e. Propylene Glycol f. Dibasic Ca phosphate dehydrate 13. Nuts a. Cashew nuts b. Pista c. Almond 14. Essence 15. Others a. Chives b. Black powder 16. Packing material a. Cardboard boxes b. Laminated rolls c. 3-ply liners All the ingredients are first received by storage department and a receipt slip of ingredient is sent to Quality control lab to check the Quality of ingredients. The total production of BIL, Rudrapur is around 250 tons. The consumption of various ingredients per day is-

8.

     

175 tons of wheat flour 55 tons of sugar 40 tons of palm oil 4 tons SMP 4 tons of cashew 4 tons of palmolin oil

There are also 2 cold stores in the plant for the storage of edible chemical like butter, compressed yeast, chocolate, Vanilla, Cocoa etc. flavors. There is silo for the online storage wheat flour with the capacity of 60 tons. There are 6 tanks of capacity 40 KL each for palm oil. For the oven system there are 4 tanks of fuel (L.D.O. and L.V.F.O.) with the capacity of 50 KL each. In the pre mixing area following tanks are present:    Palmolin oil (2 in no.) Sugar solution (1 in no.) HVO (1 in no.)

Acceptance criteria of ingredients

1. Wheat flour  Moisture %: 14% (max)  Total ash % : 0.8% (max)  Acid insoluble ash % : 0.05 % (max)  Alcoholic acidity % : 0.12 % (max)  Gluten (dry weight basis) % : 7.5% (min)  Germ oil acidity % : 15 (max)  Granularity % : 85 mesh sieve (90% should pass through)  Sedimentation value : 17-30  Taste and color: Should be characteristic.  Extraneous material: Should be absent.  Origin: Should be vegetable origin 2. Palm oil  FFA % : 0.10 % (max)  Moisture % : 0.10 % (max)  Peroxide value :1.5 (max)  Saponification value : 195-205  Iodine value : 45-56

 Melting point : 370 C 3. Sugar  Moisture % : 0.1%  Total sugar % : 99.5% 4. Baker s yeast  Moisture % : 7.5%  Dough raising capacity: 125 (min)  Fungal -amylase activity: 800-920 FAU/gm. Table standard moisture content for ingredients: Ingredients 1. Flour 2. Maize Starch 3. Sugar 4. Liquid glucose 5. SMP 6. FCCM 7. Whey powder 8. Compressed yeast 9. Carmel 10. GMS 11. Free flowing salt 12. Iodized salt 13. ACP 14. Citric acid Monohydrate Anhydrous 15. Potassium iodide 16. Calcium carbonate 17. Cashew bits 18. Almonds bits 19. Pista 20. Alkalined cocoa powder 21. Dehydrate chives 22. Ethyl vanillin 23. Chocolate 24. Cocoa mass Moisture content (max.) 14 13 0.1 16 5 29 5 75 45 2.75 0.1 1.25 1.25 8.8 0.5 1 2 5 5 7 5 7 10 3 3

STANDARD AND CERTIFICATIONS IN BIL, RUDRAPUR

ISO22000:
ISO22000 is intended to define the requirement for companies that desire to exceed the regularity requirement for food safety. It is an international standard for any business in food chain from farm to far and it include organization such as producers of equipments, packaging, cleaning agents, additives and ingredients. ISO22000 is also for companies seeking to integrate their quality and food safety management system.

Following are the benefits of ISO22000 for any organization are:

             Applies to all organization in the global food chain. A truly global standard. Provides potential for harmonization of national standard. Covers the majority of requirements of the current retailer food safety standard. Complies the codex HACCP concepts internationally. An audible standard which provides a framework for third party certification. Audible standard with clear requirement. Suitable for regulators. The structure aligns with the management system clause of ISO9001 an ISO14001. Enable communication about hazards with partners in the chain. Better planning, less post process verification. Improved documentation. Dynamic communication on food safety issue with suppliers, customers, regulators and other interested parties.

ISO9001:
The ISO9000 standards were brought by international Organization for standardization & HACCP standard by the code alimentation commission (CAC). ISO9000 encompasses all the activities of a company to ensure that it meets the quality objectives with HACCP is directed toward ensuring food safety application of HACCP adds value of the ISO9000 quality management system. A combined effect of both would provide safe & wholesome food to the consumer. Therefore the best way to use ISO9000 rout to manager HACCP

PFA 1954:
It is the prevention of Food Adulteration Act 1954. The rules were formed in 1955; this law was made to prevent any kind of food adulteration and to make laws which are applicable equally to all. The regulation regulates product manufactured, packaging, storage & sale of foods & food products. Food is said to be adulteration: y y y y y y y If it contains poisonous/injurious material. If it contain filth or decomposed material. If it contain harmful or unapproved material. If it is misbranded. If it contaminants exceed the permissible limits. If additives are added in exceed. If it is package in unsuitable packaging material.

Directorate General Health Service comes under Dept. of Health & Family Welfare is the nodal agency for PFA central committee for food standard is responsible for formation/ amending the food laws under PFA.

Hazard analysis and critical control point (HACCP):

It is a systematic preventive approach to food safety and pharmaceutical safety that addresses physical, chemical and biological hazards as a means of prevention rather then finished product inspection. HACCP is used in the food industry to identify potential food safety hazards, provide method to remove them, define their critical limits, methods for verification and documentation. So the key actions, known as Critical Control Point (CCPs) can be taken to reduce or eliminate the risk of hazards being realized. The system is used at all stages of food processing including packaging and distribution.

New concept like 5S i.e. SEIR I: Organization, SEITON: Neatness, SEISO: Cleanliness, SEIKETSO: Standardization, SHITSUKE: Discipline, are being implemented in BRITANNIA INDUSTRIES LIMITED.