INTERNSHIP REPORT

ON

Production and Quality Evaluation of Different Bakery Products

AT

Dawn Bread Industry

Rawalpindi, Islamabad, Pakistan

BY

Ailia Batool

19-ARID-4484

The internship report submitted in partial fulfilment of the requirement

Of the degree

BSc. (Hons) Agriculture Food Technology

INSTITUTE OF FOOD AND NUTRITIONAL SCIENCES

PMAS ARID AGRICULTURE UNIVERSITY RAWALPINDI, PAKISTAN

2023

1
 DEDICATION

This humble effort is dedicated

To

ALLAH ALMIGHTY

To

HOLY PROPHET MUHAMMAD (S.A.W.W.)

To

MY AFFECTIONATE PARENTS

And

Honorable officer

Sir Zafar (Assistant Quality Manager)

Whose sincerity and devotion helped me to achieve this goal

ACKNOWLEDGMENT

I have my heart and deep soul to admire the blessings of the Merciful and Almighty Allah because it is
impossible to express the dignity of ALLAH ALMIGHTY into words, whose blessings grew my
ambitions and gave me caring parents, talented teachers.
I cannot put my feelings into words in praise of HOLY PROPHET HAZRAT MUHAMMAD
(P.B.U.H.) for illuminating our conscience with the essence of faith in ALLAH and for focusing all His
goodness and mercy on him.

First of all, I owe special thanks to Prof. Dr. Anwar Ahmed (Director, Institute of Food and Nutritional
Sciences, PMAS-AAUR for providing us the opportunity to gain practical knowledge through internship.

2
I am also thankful to Dr Asif who is my supervisor at department, his guidance and valuable discussions are
truly appreciated.

I owe special thanks to Mr Abdul Karim, General Manager Dawn Rawalpindi, for providing me the
opportunity for an internship at his institute.

I would like to say thanks to Sir Zafar (Assistant Quality Manager) for the dynamic supervision, the skilful
guidance and the constructive suggestions during my internship and the preparation of my internship report.
.

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Executive summary
In the previous thirty years, Pakistan's bread sector has changed dramatically. It has grown from a small-
scale bakery processing sector to a slew of industrial bread manufacturing facilities across Pakistan.
Pakistan's bread sector is rapidly expanding, and bread products are becoming increasingly popular.
Bread has become a popular alternative to rice, naan, chapatti, and paratha. Currently, packaged bread is
consumed by 5% of Pakistan's total population. The main reasons for such a low bread consumption rate are
mostly economic and cultural. The Pakistani diet includes a variety of bread replacements that are both
inexpensive and preferred by the bulk of the population.

TABLE OF CONTENT:

CHAPTER NO TITLE PAGE NO

CHAPTER – 01 INTRODUCTION TO 05
ORGANIZATION

CJHAPTER -02 TRAINING PROGRAM 13

CHAPTER – 03 PROJECT 30
CHAPTER -04 SWOT ANALYSIS 36
CHAPTER -05 CONCLUSION AND 39
RECOMMENDATIONS

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CHAPTER 01:

Preface

This internship report was written to help me comprehend, experience, and communicate the
practical knowledge I gained throughout my internship as an intern. It also shows how business
operations are carried out at production facilities to convert raw materials into final products. I
primarily concentrate on the SWOT analysis, marketing strategy, competitive strategy, and
organizational behavior in this paper. It also highlights my responsibilities as an intern and the
knowledge I gained during my internship.

Following the completion of the internship programme, an internship report was written solely
based on the practical experience. In preparing this report, I have given it my all and tried my
hardest to provide the most information possible.

INTRODUCTION TO DAWN BREAD INDUSTRY:

Overview of Organization/Industry:

Brief history:
Dawn is a family-owned business that values nutrition and taste and provides Pakistan with the
greatest quality bread products. In October 1981, the first Dawn facility was opened in Karachi
with the goal of raising awareness and demand for a variety of bread products. It wasn't long
before the name was associated with 'Vitamin Enriched Bread,' and in 1985, a second plant was
opened in Islamabad. Dawn has continued to achieve feat after feat since then, capturing 35
percent of the consolidated market share of all bread products in Pakistan within a decade of its
founding. Dawn's quality products are now available from the southern tip of Pakistan to
Peshawar in the north.
For purpose of standardization, the company associated itself with FMBRA of United Kingdom
in 1990 to bring itself in line with international standards of production, technology, machinery
and formulation.

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Introduction to Industry:

Dawn Bread is the only brand in Pakistan that delivers freshly made bread in all three provinces
and has been doing so for nearly four decades. We understand the importance of nutrition and
taste those consumers need and deserve as one of the most established manufacturers of bakery
products, and we aim to deliver premium quality and freshness to fulfil their highest
expectations.

Dawn Bread has earned a household brand in recent years. With our thriving sibling firms Dawn
Foods (a frozen foods manufacturer), Bread & Beyond (a retail bakery franchise), and the newly
launched international brand, Dough story, we have further diversified and reinforced our market
position (a manufacturer and exporter of frozen food and bakery products).

Our iconic Vitamin Bread, Healthful Bread, burger buns, tea cakes, cupcakes & muffins, rusks,
frozen parathas, and other confectionaries are among Dawn Bread's ever-expanding collection of
delightful bakery assortments.

Policy of Industry:

Dawn Bread’s long-lasting commitment toward consumer approval or satisfaction is evident and
initiation of bringing Pakistan the world’s most technologically advanced baking units and
processes. Dawn Bread uses quality ingredients to make products with quality standards that are
comparable to bread manufactured in any developed region of the world.

To provide quality products to customer and explore new Markets to promote/expand sales of the
company through good Governance and faster a sound and dynamic team, to achieve Optimum
price of products of the company for sustainable and equitable Growth and prosperity of the
company.

We work together as a team for implementation and continual improvement of total quality
system to achieve satisfaction of our internal and external customers.

Our food products are made in a clean and hygienic environment meeting highest level quality
standards i.e., HALAAL and Food Safety Management System (ISO 22000:2005)

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List of products:

There are many sections in the industry which takes part in products making

 Bread section i-e, milky bread, sandwich bread, multigrain bread, bran bread etc.
 Burgers and buns a vast variety of burgers and buns are manufactured their plain buns
harvest buns etc.
 Sheer mall
 Fruit cakes
 Plain cake
 Cupcakes and muffins
 Biscuits
 Bread sticks i-e brown sticks and white sticks.
 Tortilla
 Garlic bread
 Soup bowl buns
 Pitta bread
 Bakar-khanni
 Mini pizza bread and many other products were manufactured there.

Every section has a proper management, workers, employees, machinery. Each department
performing their daily task of product making in a very peaceful and smooth way. Clean and
safe ingredients, free of germs, bacteria and spoilage were used during product
manufacturing. Maintaining the clean environment and hygiene. Manufactured products were
under observation until they were packed or dispatched. Quality managing, packaging,
dispatches were highly maintained.

BAKERY MACHINERY:

The main bakery products which Pakistan importing is the bread machinery the other bakery
machinery which the Pakistan is importing are the followings:

1. Rack oven
2. Spiral cooking conveyer

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 3. Slicer machines
4. Planetary mixers
5. Spiral dough mixer
6. Proofer
7. Deck oven
8. Dough divider
9. Rounder
10. Racks etc.

Competitors

There are different competitors in different areas of Dawn bread. In Lahore and areas, Bunnies
bread is the strongest competitor. Besides, there is CITI Bread, VITA Bread, Shezan Bakers and
Gourmet Bakers and some other non-branded bakeries and bread producing firms are also
included. Bake Parlor is another leading competitor in current period.

Certification of industry:

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Organizational structure:

Number of employees

1500 plus

Main offices

1. Marketing and Export office

2. Accounts office

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 3. Administration and Human Resource Department.
4. Time Office
5. Electricity office
6. Mechanical Workshop office
7. Stores (General Store, Chemical Store)
8. Security
9. Gate Pass Office

Introduction to all departments:

 Production department
o In production department, all bakery products are manufactured by following
different recipes for different products.
o Raw material is being collected at production place after screening and testing.
o Raw material has been passed from different control points to ensure safety and
quality.
o Once all ingredients are ready, all workers start working right from mixing
ingredients, adding right amount of water, molding, baking, cooling and
packaging.

 Quality department
o It ensures quality and safety of all raw materials, packaging materials and final
end products by passing through different critical quality points and other safety
phases.
o Inspection of raw products at receiving time and delivering time is done at quality
department.
o First in Fist Out (FIFO) is also done with raw materials in store.
o Raw materials and end product is been ensured by legal regulatory body like
(PFA).
o Testing of products like micro-testing, moisture testing, gluten testing, nutritional
information is done in this department.

 Marketing department
o Marketing is a way of concentrating an organization's efforts and resources on a
course of action that can result in greater sales and market dominance in a
specific market niche. A marketing strategy involves product creation, promotion,
distribution, pricing, relationship management, and other factors; it specifies the
firm's marketing objectives and describes how they will be met, ideally within a
certain timeframe.

 Sales department:
Sales department is further divided into two departments:

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 o Retail department
It delivers the product to local market.
o Horeca department
It includes all major areas like KFC, Hardee’s, McDonald’s and ranchers etc.

 Accounts department
o In this area all the purchasing, selling of raw and final products, payments of
workers, receiving orders is done by sale workers.
o A monthly payment is sent to workers’ accounts on time.
o Records of all prices of products sold and purchased are kept in accounts
department.
o Auditing of accounts department comes under audit department

 HR+ admin department

o HR and admin monitor all the workers and other activities happening in industry.
o It also provides workers and interns with job or work description and salary
definition.
o They also monitor security and ensure working of cameras.

 IT department
 All the internet related job is been done by IT department like networking in
industry like working with emails, online communication, camera and other
electrical equipment working, thumb printing etc.

INTRODUCTION TO BRANCH:

Dawn Bread provides fresh bread to 3 main provinces. I worked as internee in Islamabad branch
which is located near Quaid e Azam international hospital. After Karachi in 1981, Dawn bread
industry grew their industry in further cities and Islamabad branch was established in 1985.

RAWALPINDI OFFICE:
Capital Foods (Pvt.) Ltd.
15-E, Nasirabad, Peshawar Road, H-13, Rawalpindi, Islamabad Capital Territory, Pakistan, and
West Punjab

Tel. : 92-51-111-111-999

Fax : 92-51-5472652

E-mail: islamabad@dawnbread.com

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Starting and ending dates of your internship

Internship was started on 1st March 2023 and ended at 22 APRIL 2023 (Two months).

Names of the departments in which you got training and the duration of your training

Basically, I was approved to work in two major departments;

 Production department
 Quality department.

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CHAPTER 02
TRAINING PROGRAM:

I worked in production department and quality department as an internee. In production

department I saw the workers manufacturing/ baking of various bakery products. Right from
receiving raw material and collecting ingredients and mixing them in correct proportion until the
final baked product is produced and supplied to market.

Product lines of dawn bread:

 Breads:
Initially they started with dawn bread but now have 4 different variants based on their
ingredients.
Ingredients: flour, salt, sugar, milk, yeast, water, oil and preservatives
 Plain bread:
There are 3 different plain breads; large, medium and small.
 Bran bread:
It adds fibers in life. It is freshly baked and ideal for good consumption of fiber in our
daily balanced diet.
Ingredients: wheat flour, wheat bran, multigrain, yeast, salt oil and preservatives.
 Fortified bread:
It is freshly baked, wholesome bread contributing essential nutrients to our balanced diet.
It is multi-purpose bread that can be used for breakfast, lunch, dinner and snacks.
Ingredients: flour, sugar, vegetable oil, bread emulsions, yeast, vitamins and
preservatives.
Size: small, medium and large.
 Milky bread:
It is made by adding extra milk which gives extra taste to each slice of bread.
Ingredients: flour, sugar, salt, milk powder, vegetable oil, preservatives, artificial flavor
and food color.
Size: small
 Plain white bread:
This freshly baked bread was the first bread to be introduced in Pakistan market by Dawn
industry.
Ingredients: flour, sugar, salt oil, yeast and preservatives.
Size: small and medium
 Burger buns:
These are freshly baked with enriched nutrients and supply to large market all over
Pakistan.
Size: burger package of 2 buns, special package of 4 buns.

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  Cupcakes:
Ingredients: wheat flour, vegetable oil, milk powder, leavening agent, water and salt.
Size: 2 in a pack, 6 cupcakes in a pack
Flavored cupcakes that include chocolate cupcake, strawberry cupcake, pine apple
cupcake, and mango flavored cupcake.
 Rusk:
The first packaged Rusk to be sold in market:
Ingredients: wheat flour, sugar, vegetable oil, vegetable shortening, milk, salt, yeast,
preservatives, natural and artificial food flavor.
Size: medium
 Tortilla
Flour, water, oil, salt and preservatives.
 shawarma bread:
Flour, yeast, sugar, salt, oil and preservatives.

BREAD RECIPE:

Over the years, the production of bread has become increasingly more complex with a multitude
of additions ranging from fruits to nuts and many other kinds of flours. Bread is a staple food in
many countries including Pakistan where it is a important part of breakfast. There are five main
steps in the production of bread mixing, shaping, proofing, scoring and baking.

There are many types of breads including garlic bread and bran bread. Typically, bread is 60-75
% water by weight depending on the desired consistency. Bread also has fat added at a level of
3% in order to soften the structure and also to support the development of gluten. Salt is added to
almost all the formulas to enhance the flavor and strengthen the development of gluten yielding a
higher quality product for consumers.

The basic ingredients are flour, yeast, salt and water. Bread improves (flour treatment
agents), usually vitamin c (ascorbic acid), are used in commercial production.

 Flour:
Flour provides the structure for the product. The gluten (protein) in flour,
combines to form a web that traps air bubbles. Starch in the flour after heating
supports the structure. In yeast bread, the goal is to get a lot of gluten formation,
since it forms a stretchy web that traps carbon dioxide and steam during baking.
This gives bread its texture (also known as "crumb"). Fats and sugars help
prevent gluten formation. There is also some simple sugar available in flour and
this feeds the yeast.

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 Bread flour is high flour protein and it produces bread that has a higher volume
because it contains more starchy gluten. Bread that are produced with bread
flour rest for 15-20 minutes after rising and before the shaping of the loaves so
that the gluten relaxes a bit and then the dough is easier to work.
All-purpose flour works just fine for almost all breads. It is good for home
bakers; the only difference is gluten content between all-purpose and bread flour
is typically just 1 percent.
Whole grain flour does not have much gluten because there are other ingredients
like bran and germ which get between the gluten molecules, whole grain flour is
usually combined with bread and all-purpose flour so that it will make a better
crumb.

 Yeast:
Yeast is a single-celled plant that comes in dry, instant, and live forms. Yeast
multiplies and thrives in yeasted bread by utilizing available carbohydrates and
water. Through a process known as fermentation, it emits carbon dioxide and
ethyl alcohol at the same time. The yeast multiplies as long as there is air
available. The dough is supposed to be "pushed down” in bread recipes that rise
a second time. This disperses small clusters or colonies of yeast cells, allowing
them to acquire more air and nourishment. As a result, the second ascent is often
shorter than the first.
Many bakers believe live yeast cakes results in a more flavorful product. Cake
yeast, on the other hand, degrades quickly and should be used within a day of
purchase. Cake yeast can also be frozen. Active dry yeast would be the second
choice for most bakers. It produces a more flavorful product than quick yeast.
Instant-rise yeast has been genetically modified and comes with its own source
of food. When it is rehydrated with fluids, it becomes active immediately. This
yeast is incredibly convenient; however, the rate of rise is so rapid that little
flavor develops during fermentation.

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 Salt:
Salt is a key component of bread, and it's critical that it's measured correctly. If
you're trying to eliminate salt out of your diet, bread isn't the place to start. But
don't worry; most recipes just call for 1 teaspoon. Salt strengthens gluten and
improves the flavor of bread dough. In yeast bread, salt serves to temper the
yeast's action, preventing the bread from rising too quickly. It is known as a
"retarder" in this position because it slows down the yeast, allowing the dough
to develop flavors and not become out of control.
 Fat:
Oils, shortening, and butter are the most frequent types of fat used in bread. The
fat coats the gluten molecules, making it difficult for them to combine. This
contributes to the softness of the ult imate product. Yeast bread with a high fat-
to-flour ratio is significantly more tender, doesn't rise as high, and has a tender
mouth feel. Fat also imparts flavor to the bread and aids in its browning during
baking.

 Sugar
Sugar adds sweetness and aids in the browning of the bread. Sugar's primary
function in yeast bread is to supply sustenance for the yeast. As the yeast grows
and multiplies, it consumes the sugar, producing carbon dioxide and alcohol as
byproducts, which give bread its distinct flavor. Sugar softens bread by limiting
the formation of gluten. It also helps the completed product retain moisture.

 Eggs
Some bread recipes, but not all, call for eggs as a leavening agent. When a lot of
eggs are used, the flavor of the completed product is enhanced, and the bread is
often very rich. The egg yolks also contribute fat to the dish, making it soft and
light. Yolks also work as an emulsifier, giving the finished product a smooth
and equal texture. Some breads include yolks as well as whole eggs.

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STEP 01: MIXING:

The goal is to blending and hydrating dry components, include air, and create gluten for optimal
dough handling properties. Mixing time, energy input, and dough temperature are all variables to
keep an eye on and control.

 Mixing time is determined by flour strength, protein content, damaged starch and non-
starch polysaccharides, and the presence of bran particles. Mixer speed, mixing arm
design, dough size in relation to mixer capacity, refrigeration system adequacy (dough
temperature), and delayed sugar/fat/salt addition are all issues to consider.
 Mixing equipment: Vertical (planetary), spiral (open and closed for vacuum mixing),
horizontal, continuous mixing equipment (open and closed).
 Process time: 9–15 minutes in horizontal mixers at high speed. The final temperature of
the dough should be 76–82°F (25–28°C).

Fermentation

The objective is yeast growth, production of CO 2, ethanol and organic acids, development of
flavors and aromas, and modification of dough handling properties. Variables to monitor and
control include fermentation time, temperature, titratable acidity (TTA), pH, microbial count:

 Fermentation time: controlled by the temperature of dough, sponge, starter or pre-

ferment, hydration level (free water), pH, osmotic pressure, yeast food (amino acids,
minerals, fermentable sugars) and yeast level (or lactic acid bacteria count).
 Fermentation equipment: troughs in fermentation room, closed tanks, open tanks,
benches.
 Process specifications: 1–20 hours (at room conditions), depending on dough system
used. The temperature in fermentation rooms is typically set between 75–85°F (24–29°C)
with a relative humidity (RH) of 60–80%.

STEP 02: MAKEUP AND

DIVING

Makeup stage mainly encompasses

four operations:

1. Dividing
2. Rounding
3. Intermediate proofing
4. Sheeting and molding

The divider cuts bulk dough into

single pieces of proper weight
(with as little stress exerted on
dough as possible) so that these can
be rounded and rested prior to

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taking their final shape. The divider
must process the entire dough load
quickly to prevent excessive gassing
that creates scaling errors.

The sheeter and molder encompass the

sheeting stage, curling chain, pressure
board, and guide bars. These influence
the gas bubble structure, shape and
length of the dough piece to place in
the pan. The molder should be
adjusted to achieve the desired shape
with a minimum amount of pressure
and stress on the dough to avoid
damaging cell structure obtained
during mixing and fermentation.

STEP 03: BAKING

The objective is to convert raw dough into bread, set structure of product, crust and crumb
formation, kill-step and shelf-life extension. Variables to monitor and control include
temperature, time (governed in continuous ovens by conveying speed). Other relevant variables
include heat flux (burners), humidity (dampers) and air velocity or flow.

 Baking time: controlled by oven temperature, conveying speed, initial (proofed dough)
and final product temperature, heating pattern, bake loss, product load and formulation.
 Baking equipment: direct-fired oven, indirect-fired oven, electric oven, rack oven, reel
oven, conveyorized, tunnel, hybrid and impingement oven.
 Process specifications: 10–20 minutes at 400–420°F (204–216°C) (heating pattern in
different ovens must be equivalent for comparable results).

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STEP 04: COOLING

After baking the bread from

the oven is placed in industrial
spiral cooling conveyer that
cools down the bread. Bread
cooling is a crucial step in
bread production, the
temperature of the bread is
decreased from 93-97◦C to 32-
43 ◦C. This step allows the
finished product to achieve
optimum keeping quality and
comply with the acceptable
mo isture limit of 38%. As the
loaf cools down some of the
mo isture moves towards the
crust which becomes softer.
Cooled bread is then
immediately sliced, bagged and
packaged. [1]

Bread cooling time is a function of size and shape of the loaf. Denser and bigger pieces
require longer cooling time (slower conveyor speed while maintaining other cooling
variables).

Cooling variables that are controlled:

 Cycle time (related to conveyor speed in continuous operations in spiral

conveyor coolers).
 Relative humidit y and temperature
 Air flow

Inadequate cooling can negatively impact the quality of baked product as well as the
overall bakery operation. However, inadequate cooling can result in dry finished
product and harsh eating qualities. The dryness and loss of moisture contributes to a
faster loaf stalling.

Effects of insufficient cooling:

 Pilling of the crumb

 Slices will be ragged and may tear due to excessive moisture remaining in the
loaf and the crumb being too soft.

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  Excess moisture due to condensation in the wrapper.

STEP 05: SLICING AND PACKAGING

Machines can cut a variety of breads, including white, rye, and mixed breads, as well
as fruits and vegetables. Depending on the machine model, sliced bread loaves can be
produced at speeds ranging from 200 (semi-automatic versions) to 2000 (bread cutting
and packing lines). Special bread slicer models with circular round knives allow you to
cut the bread to your desired slice thickness, ranging from 5 to 25 mm in 1 mm
increments. These models are particularly popular in shops that want to provide the
finest possible quality and service to their customers, as well as in smaller or medium
bakeries that want to cut unusual bread, such as very soft or very hard bread or bread
with special additives.

The following are a few common bread slicing issues:

 Guides that are misaligned, causing the slice size and count to be inaccurate.
The number of slices per bag can be reduced or increased if the slicer guide is
set incorrectly. A product with too thin slices can collapse throughout its shelf
life.
 Blades that are dull or missing can be a major problem. Blades must be honed
and replaced as needed, depending on the situation. Because some inclusions,
such as pre-hydrated fruits, might cause gumminess, appropriate blade cleaning
during changeover time is essential.
 After cooling, the product has a high temperature. Slicing issues might occur if
the product temperature is not within the intended range of 30–36°C (86–97°F).

If the loaves are overheated;

 The crumb will be excessively soft, and little particles of doughy crumb may
clog up the slicer blades.
 The slice is jagged and prone to tearing (rough surface)
 The sidewalls are flimsy and could collapse.

If the loaves are too cold;

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  There will be too many crumbs at the slicer, resulting in product loss.
 Excessive moisture loss will result in drier and harder bread.
 The bread will not be as soft as expected by the customer.
 Higher doses of crumb softening amylase should be tried if this is a persistent
problem.

Every bakery's slicer settings are different for each type of bread they manufacture. As
a result, bakers should utilize a set-up chart that specifies the settings in order to
achieve precise results. Adjustments that are commonly made include:

 The width of the slice

 Hold down the infeed
 Depending on the size of the goods, there are side guidelines (especially loaves
length)
 Timing with a paddle
 Oilers, honers, replacements, and tension can all be modified or changed when it
comes to blades. To maintain optimal slicing qualit y, all of these elements must
be monitored and maintained on a regular basis.

When the blades are replaced and the blade tension is established, there will be some
downtime. A band slicer's blade tension is usually 60–70 pounds per square inch (psi).
The blades' life will be shortened if the blade tension is not properly set.

The bread is then packaged and then marketed to different shops and restaurants.

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 FLOW CHART FOR BUN:
SIFTING
Demand from Material
production requisition
MIXING

Demand to purchase/ Purchase

DOUGH DIVIDING
store requisition

Issuance of
Incoming of material
material MOLDING
Production
inspection
Quality inspection Store PANNING report
requisition

PROOFING

Internal External
DRESSING

QUALITY COA BAKING

REPORT REPORT

PACKAGING HC

DISPATCH
COMPILATION OF
REPORTS
Inspection
QUALITY report

NO YES Goods
STORE receiving
decision Receiving of
supplier notes
ingredients

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 FLOWCHART DIAGRAM FOR CUP CAKE:

Demand for Material

Sifting Egg HCP 02
production requistion
breaking

Demand to Purchase
purchase/ store Mixing HCP 03
requistion

Incoming of Issuance of Molding

material material

Quality inspection Baking

Store Production
requistion inspection
Cooling report
Internal External
Garnishing

Quality report COA report HCP 04

Packaging

Inspection
Compilation of Dispatch report
report
Quality Goods
receiving
yes notes
Supplier Decision Receiving of Store
ingredients
HCP 01

1- CAKE:

Types of cakes:

 Plain cake
 Fruit cake
 Mini fruit cake
 Mini plain cake

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  Large cake

Recipe ingredients:

 Eggs
 Sugar
 Milk powder
 Maida
 Baking powder
 Cake gel
 Butter sense
 Potassium sulfate
 Glucose
 Citric acid
 Salt
 Glycerin
 Oil
 Cp
 Ice/water
 Muraba (for fruit cake)

Mixing:

 Temperature for mixing must be 25C

 Time for mixing sugar and eggs is 5 minutes, oil (3 minutes), and Maida (2 minutes)
 Total mixing is done in 9-10 minutes.

Baking:

 Baking time is 30-35 minutes.

 Temperature for baking is 200-205 C

Packaging:

 145 packets per batch

 150 packets fruit cake

2- CAKE RUSK:
Recipe:
 Sugar
 Cream

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  Lemon juice
 Butter sense
 Salt
 Maida
 Egg
 Oil
 Milk
 Baking powder
 Food color
 Ice/water

Mixing:

 Total time for mixing is 30 minutes

 Temperature during mixing is 20C

Baking:

 For baking J4 oven at 150C

 Burner 1: 170 C
 Burner 2: 160C
 Time taken in baking is 30-35 minutes

Packaging:

 A single batch consists of 100 packages.

 1 packet has 14 pieces.
 Expiry time is 2 months

3- BAKAR KHANI:
Recipe:
 Maida
 Water
 Oil
 Salt
 Eggs
 Margarine

Time:

 15 minutes mixed at normal temperature

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Baking:

 45 minutes per trolley

 Temperature is 250 C

Packaging:

 220 packets per batch

 1 packet has 2 pieces
 Expiry is after 1 month.

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QUALITY TESTING LAB
WORK:

1- GLUTEN TEST
 For gluten test, we
took 22 g of flour
sample and 8 ml of
water.
 Then we put the
sample of flour in a
Petri dish and
added water.
 After adding water,
we made a dough
with hard and thick
consistency.
 After forming
dough, we gave it a
round shape.
 Then washed it with distilled water not too cold neither too hot.
 Starch will be washed away with the dist illed water.
 As gluten cannot be washed away it will get a shape of cluster.
 Then put the wet gluten in a Petri foil dish and weigh it.
 Weigh of the wet gluten is 4.234 g.

2- MOISTURE TEST
 For moisture test we simply take a Petri foil dish.
 We put flour sample in it and make an even layer from the upper side.
 After this, we put the sample in a automatic mo isture analyzer and it will
give us the percentage of moisture in the given sample.
 The moisture for the sample of flour is 14.41 %

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 3- Flaming test for eggs:

Candling is a process in which bright light is passed through the eggs to see if the egg
is healthy or not. Candling equipment doesn't need to be very fancy or specific - in

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fact, in the old days it used to be done with the flame from a candle (hence the name).
The main requirement is a bright light (the brighter the better) with an opening smaller
than the diameter of the eggs you intend to candle.

There are two possible results:

1- If the eggs are rotten or spoiled it will show an orange veins like appearance
showing that the egg is not suitable for bakery purpose and is wasted.
2- When the light passes through the eggs and it shows no cracks and no orange
veins like appearance that the egg is suitable for further processing.

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CHAPTER 03:

TASK ASSIGNED:
1- Implementation of Halal and HACCP:

The scope of the HALAL Management System starts from receiving of Halal / natural
ingredients, proper identification and traceabilit y system is applied on Halal
ingredients / raw material, then process of Halal ingredients is done as per Shariah, and
then final products is shifted to, processing, and packing whichever is required as per
the customer demand. Lastly Halal product is dispatched to designated locations in a
hygienic and Halal manner.

 Halaal: Things or actions permitted by Laws of Islam.

 Tayyib: Things
o That are intrinsically and naturally liked by the Muslims;
o Those are safe, delicious, pure, and nutritious and permitted as per the
Laws of Islam.
 Haram: Things or actions strictly prohibited by Laws of Islam.
 Khabith (Abominable): Things:
o That are abominable and intrinsically and naturally disliked by the
Muslims;
o Those are prohibited by the Laws of Islam, for example insects, pests,
etc.
 Tahir: A thing that is neither Najis in itself nor is contaminated with a Najis
thing.
 Najis: A thing that is abominable in itself from the Shariah point of view or is
contaminated with such substances. khamar (wine), carrion, any discharge from
the orifices of human beings or animals such as urine, excreta, blood, vomit,
pus, sperm, ova, and any other thing that is extracted, derived or a by-product of
such substances or coming in contact with such substances.
 Mashbooh (Mushtabeh): Mashbooh means 'doubtful' or 'suspected'; when it is
unclear whether the product in question is Halaal or Haram.
 Makrooh: Makrooh means prohibited and disliked in the Laws of Islam. There
are two categories of Makrooh
o Makrooh-e-Tahreemi: It is prohibited and disliked as per Islamic Laws
and is very close to Haram;
o Makrooh-e-Tanzeehi: It is disliked as per Islamic Laws and is close to
Halaal but better to avoid it

Difference between Halal and Haram food product:

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Halal Product: Halaal products including food and drinks but not limited to them,
allowed to be consumed as per Islamic Laws, which fulfills the following conditions:

 The product or its ingredients do not contain any parts or products of

animals that are non-Halaal or products of animals which are not
slaughtered according to the Laws of Islam;
 The product does not contain any ingredients that are “Haram” or
“Najis”;
 The product is safe and not harmful for human health;
 The product is not prepared, processed or manufactured using
equipment contaminated with things that are “Haram” or” Najis”;
 The product or its ingredients do not contain any human parts or their
derivatives;
 During its preparation, processing, packaging, storage or
transportation, the product does not come into contact with any Haram
or Najis items that can contaminate it.

Haram Foods: Products including but not limited to food and drinks, strictly prohibited
by the Laws of Islam that contains:

 Haram animals;
 Halaal animals that have not been slaughtered in compliance with the
Shariah requirements;
 Seven parts of Halaal animals slaughtered in compliance with the
Shariah requirements, namely blood, urinary bladder, gallbladder,
glands (i.e. ghudood in Arabic), penis, testicles and vulva;
 Those things that cause intoxication such as wine, liquor etc.
 Things that harm the human body or intellect to such an extent as
cannot be neglected;
 Things abominable to human beings, for example, nasal secretion,
insects, pests, etc.
 All human parts such as hair, nail, and organs or their derivatives;
 Things that are Najis (i.e., filthy) as per Shariah laws such as faces,
urine etc.

Micro-Organisms & Microbial Product

• All species of micro-organisms are Halaal except those that are poisonous,
intoxicating or hazardous to health;
• Microbes which grow on a Halaal growth media are Halaal and which grow on
Haram growth media are Haram;

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 • Microbial consumer products which use Haram and Najis materials on its growth
media in all production steps (refreshing scale, pilot plant scale and production
stage) are Haram;
• Consumer products containing microbial products which grow on non Halaal
media are Haram;
• Consumer products containing microbial product shall be traced back to initial
growth media of the microbes;
• Microorganisms are Halaal except those that are poisonous and/or hazardous to
health (pathogenic and toxicogenic);
• Microorganisms or their products used in food or food production shall be
produced using Halaal culture medium.

Prerequisite Programs (PRPs): Basic conditions and activities which are necessary to
maintain a hygienic and valid environment from Shariah point of view throughout the
food chain suitable for production, handling and provision of safe Halaal products:

Good Manufacturing Practices (GMP): Actions regarding personnel hygiene and

sanitation in the processing premises to ensure Halaal, safe and healthy production,
storage and distribution of foods as defined in relevant

Pakistan Halaal standards along with “PS:1825 for Good Manufacturing Practice in
Manufacturing Processing, Packing or Holding Human Foods”

Good Hygiene Practices (GHP): Measures taken in stages of food chain to ensure the
provision of Halaal and safe food for consumption as per relevant Standards on Halaal
and Code of hygienic Practices.

Food Safety: Concept that the food will not cause harm to the consumer when it is
prepared and/or eaten according to its intended use.

Halaal Food Safety Policy: Overall intentions and directions of an organization

related to Halaal Food Safety as formally expressed by top management that shall be
Muslim(s) OR, Senior Management shall appoint a Halaal

Management Representative who shall be a Muslim and responsible for the overall
implementation of the Halaal Management System.

Food Chain: All stages involved from farm to fork in the production of food and
drinks including primary production, harvesting, preparation, processing, packaging,
storage, transportation, distribution and supply to the market.

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Halaal Chain: All stages involved, including but not limited to primary production,
preparation, processing, packaging, storage, transportation, distribution and supply to
the market as per Islamic Laws.

End Product: Product that will undergo no further processing or transformation by the
organization

In case of hygiene, sanitation and food safety measures were implemented to:

 Control contamination from all sources including air, soil, water, machines and
workers.
 Protect food sources from pests, fecal and other contamination.
 Manage waste effectively, and
 Store harmful substances appropriately.

In case of packaging and labeling, following requirements were fulfilled;

 Not prepared, processed or manufactured using equipment is contaminated with

things
 During the preparation, processing, storage or transportation of the packing
material, it is ensured that the material is physically separated from any other
packaging material that does not meet the requirements stated in above points.
 It does not transmit toxicants to the product.
 Packing process is carried out in clean and hygienic manner and in sound and
sanitary conditions.
 Labeling material that is used in direct contact with the product does not impart
any color, flavor and toxicity to the product and is made from the halal source.

Each packet is labeled with the following information;

 Name of the product

 Net weight
 Name, address and trademark of the manufacturer of local origin.
 List of ingredients in descending order of the proportion by weight.
 Code number, identify date and batch number of manufacture, expiry date and
country origin.

HACCP IMPLEMENTATION:

HACCP is a management system in which food safety is addressed through the analysis
and control of bio logical, chemical, and physical hazards from raw material
production, procurement and handling, to manufacturing, distribution and consumption
of the finished product.

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 Hazards need to be classified into three categories, BIOLOGICAL (including bacterial
pathogens, viruses), PHYSICAL or CHEMICAL and assessed systematically. In this
example, the meat could be physically contaminated by the structure of the premises (dust
and dirt), chemical hazards in the form of residues, could pose a hazard, and the presence
and the outgrowth of bacteria is constantly present.

Significance of identified hazard to the product:

The severity aspect of an identified hazard relates to its capacity to cause harm to the
consumer. Chemical residues exceeding established Maximum Residue Limits similarly
have a high level of severity. Pieces of bone (Physical Hazard) may be assessed to be a
medium-to-high severity. The risk aspect of an identified hazard relates to the probability
or likelihood of the hazard occurring at the step, taking into account the premises specific
conditions. Answers to these critical questions require sound understanding of the product
and its processes.

Control measures need to be taken to prevent, reduce or eliminate the hazard:

Control measures (also known as preventive measures) will vary on the type of hazard
and obviously their significance, however in the above example the control measures
centre around sourcing the product from approved suppliers, keeping it at the correct
temperature and maintaining the premises to an acceptable standard of hygiene. In some
cases, there will be more than one control measure for an identified hazard, and
conversely, more than one hazard may be controlled by a specified control measure.

If a subsequent step in our process eliminates or reduces a hazard, then a CCP at the
original hazard point is not required e.g. a cooking or sterilization step to eliminate
bacteria. The number of CCPs required for control can thus be minimized

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 2-Monitoring maintenance day work:

On maintenance day that is every week Thursday, all the machinery is completely
cleaned and production is very less. It was our task to monitor that every part of
machinery is completely cleaned and flours are cleaned.

35
CHAPTER 04

SWOT ANALYSIS:
1. STRENGTHS
 Leading Bread Brand owning the evolution of bread in Pakistan holding a market
share of 35%.
 Early adopters of new technology, advanced production units with experienced
food technologists proving their experience in baking.
 TOM recall among Bread Brands through presence in print and presence in food
festivals, exhibitions local and international.
 Largest Distribution Network providing Nationwide coverage. Effective On time
delivery and round the Clock customer services proving professional management.
 Vast range of quality with a choice of flavors within them. Stability of production •
Less turnover of the employees
 Highly skilled labor
 Talented marketing managers
 Qualified finance staff
 Professionalism in the employees
 Motivated sale team There is complete motivated sale team in the DAWN
BREAD which always do their best job for the promotion, increasing demand,
targeting, focusing needs and according to the customer need the suggest to renew
the products, packing labeling etc.

2. WEAKNESS
 It Has been slow in acquiring efficient processes in the brand building area.
 Products launched by force of Sales Team & Competitors (when need is raised)
 Large Product Range lacking proper planning, strategy, product positioning
causing hurdles in brand building process Information Flow.
 Confused Branding resulting in the fading of image such as cakes, cookies not
being highlighted as standalone brands from the house of dawn.
 Over work burden on the employees due to limited strength of the workers.
 No employee back up plan.
 No proper medical facilities
 Consequences for efficiency and equitable distribution of growth.

36
 3. THREATS
 Low Operating cost, Trade discounts offered by the competitors.
 Barriers to entry are very low in the industry.
 Extension of accessibility networks by other brands.
 Customers have shown high affinity to better/new image brands
 Some products may lose focus in a particular category by new arrivals. As the
planning lacks.

4. OPPERTUNITIES
 Consumers are more receptive towards the change due to media and competition.
 The recent growth in RTE food sector specially baking growing varieties in RTE
food sector.
 Competitors,
 Weak Brand Loyalty,
 Product range,
 Product Quality
 To increase the skilled labor
 To use the motivational techniques. (Employee of the month, incentive plans
motivate to perform the above standard)
 To create the awareness
 Emphasizes on the business ethics.

CRITICAL ANALYSIS:

 Practical knowledge, without a doubt, is the most valuable. This internship has
taught me how business agreements are made. I am learning how to draught
contracts and agreements.
 I also gain an understanding of how operations in a manufacturing unit are
carried out. I learned about the advanced units utilized in the blade
manufacturing business, as well as the company's marketing operations.
Processes and procedures in marketing that aren't working.
 In addition, I learn about the company's export procedures for carrying the
business unit.
 Every company has its own communication phrases and jargon. You will have
sufficient confidence to work in any business environment once you have
mastered these concepts and phrases. I've made an effort to learn all of the
phrases and jargon used in dealing. However, there is still a lot to learn.

37
 Some issues were experienced; I had some issues at the start of my internship
until employees and I developed a sense of trust. But it was all okay when I
realized how welcoming the DAWN BREAD environment is. It gave me a great
deal of confidence in my ability to work as an intern. I had a hard time grasping
the phrases and vocabulary used in dealing at first. These are essentially
regional terms. As a result, understanding these terms took a long time.

38
CHAPTER 05:

CONCLUSION AND RECOMMENDATION:

Conclusion:

After doing this internship, I have concluded that working in an industry is interesting
and skillful. Working in an industry requires organized thoughts, time managing skills,
multitasking and observant behavior. My experience as an internee in DAWN Bread
industry was good. I have learned about production and qualit y both. I have learnt
about policies like HALAL, HACCP, VACCP, TACCP and ISO.

Recommendation:

 As a food technologist, my main concern is to increase the shelf life of any food
product. Controlling moisture is the one way to do it. I have noticed during my
internship in this industry, that they do not have any instruments for testing
mo isture content of final product. My suggestion is to introduce mo isture testing
of the final product so that the products shelf life can be increased or
maintained.
 The other thing that lacks in this industry is proper marketing. Each product
must be highlighted and marketed individually. Each product has its own
specialty and that is why each product must be highlighted in its own unique
way.
 Lack of lab staff is another important issue. There is no proper quality testing
lab, and the few tests that are performed are performed by some random
workers.

References:

1. Stear, C.A. “Bread Cooling and Setting.” Handbook of Breadmaking

Technology Elsevier Science Publishers Ltd., 1990, pp. 638–650.
2. http://dawnspread.com/
3. https://www.google.com/url?sa=t&source=web&rct=j&url=https://pdfslide.net/amp/docu
ments/dawn-bread- internship-
report.html&ved=2ahUKEwiT17zIxuT3AhXngf0HHdHqDlkQFnoECAcQAQ&usg=AOvV
aw1UybM7pZHACKaOYXB4q MIc
4. https://www.google.com/url?sa=t&source=web&rct=j&url=https://pdfcoffee.com/dawn-
bread-internship- report-pdf-
free.html&ved=2ahUKEwiT17zIxuT3AhXngf0HHdHqDlkQFnoECAgQAQ&usg=AOvVa
w0db9Stc6J73CzmtMyJAPHO

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