A QUALITY CONTROL STUDY ON PEREA’S ENTERPRISES

ABALOS, CONRAD KING

ANASTACIO, RHEA MAE
BINOYA, KRISTALIN
EBORDA, PAULINE JAY
GARSUTA, JOHN REYCHE
TALABOC, ROMNICK

COLLEGE OF ENGINEERING

MAY 2023
 INTRODUCTION
Perea's Enterprises is a small business scale specializing in manufacturing, marketing
and distributing consumer goods in the food sector. They are a wholesaler of first-fried banana
chips based in Purok 6, Barangay Sudapin, Kidapawan City. It was a family-run business which
roots go as far back as 2013 and has been headed by the patriarch Reynaldo Perea Jr., with
amazing clienteles today.
Their products were mainly bananas (var. Cardava) directly sold to them by the local
farmers. Some of their finished products were sold and distributed locally and even for
exportation because of its high-quality standard.
They are still in this ever-competitive food business and have upgraded their services for
the best of their clients who have supported them all these years. Their business has grown
despite having many competitors in the market. They are proud to say that they have created a
strong bond with their clients.
In the course of over 10 years, as the coveted first-dried banana chips producer in town,
Perea's Enterprises is thriving in the market with their unshakable commitment in product
development and strict quality standards.
PROCESS FLOW CHART
Selection of raw materials
 Raw materials for processing shall not contain parasites, microorganisms, toxins, and
decomposed or extraneous substance.
ü It does not show any sign of deterioration, decomposition, or contamination which
renders unfit for human consumption.
ü It is essential to use under-ripe green bananas as these have the correct texture for
drying and frying.
ü Refined coconut oil must be used for frying.

Equipment needed
• Knives or small fruit slicer
• Slicer machine
• Digital scale
• Large container for soaking fruit
• Plastic sieve for draining the soak water
• Drying table (air drying)
• Drying cabinet (for assisted drying)
• Large frying pan or wok
• Thermometer
• Polythene bags
• Bag sealer
Scaling
 Using an analog scale each batch must weights at 50 kilograms per basket.
Peeling
 Bananas should be peeled just before they are used because when the flesh is
exposed to the air it turns brown.
 Unnecessary off-specs (tibagnol) must be cut-off.
Washing
The fruits soaked in a clean water-filled container at normal temperature within 1-2
minutes.
 Do not leave the peeled bananas in the water for longer than 3-5 minutes as they
become too wet and soft and will take longer to dry.
Slicing
Using a slicer machine, manually operated, the bananas slice crosswise or diagonally
crosswise that are about 5-8mm thick.
 Try to ensure that all pieces are the same thickness so that they all dry and fry at the
same rate.
Frying
At under 140ºC, a few banana chips added to the oil (enough so that one layer of chips
fit into the pan).
With a straining spoon, banana chips were removed from the oil when they rise to the
surface of the oil and are a golden-brown color.
 Make sure that the temperature of the oil does not get too high or the chips will
burn.
 The oil should not be used for frying more than three to four times as it deteriorates
each time it is heated and this will spoil the flavor of the chips.
Draining out oil
The chips are placed into the mesh basket, this is lowered into the hot oil, shaken a little
to move the chips around in the oil and then lifted out as soon as the chips are golden
brown.
 Leave the chips in the basket to drain off the excess oil (collect this oil as it can be
returned to the fryer and re-used).
Drying and Cooling
Using two large electric fans each side, the chips were air dried and cooled in a wide
mesh.
Inspection
Dried banana chips will be checked manually by a quality check personnel, then picks-up
those rejects or off-specs according to its quality standards:
• OBC (oily banana chips)
• Black-specs
• Toasted/Overcooked
• Broken
• Stuck
*stuck chips will undergo refrying until it meets the crispness

Packing and Sealing

When the chips passed its quality standards, a weight of 10 kilograms per crates were
packed and sealed in a polyethylene plastic bags.
Ensuring that, it is:
 Cool in room temperature
 Moisture proof
 Airtight
Each bag will be labeled as locally or internationally distribute to.
Storage
 Store the bags in a cool place away from direct sunlight.
 The fried chips have a short shelf life of about 2-3 weeks, so make sure that they are
sold or consumed well within this time.
 QUALITY CONTROL CHARTS

CHECK SHEET

PEREA'S ENTERPRISES

Date: May 17, 2023

Time: 8:00 A.M. - 5:00 P.M.
Operator: Mr. Reynaldo Perea Jr.

DEFECTS WEEK TOTAL

Day 1 Day 2 Day 3 (in kilos)
Toasted/Overcooked 13 10 14 37
Broken 15 18 20 53
Stuck/Undercooked 10 9 12 31

*we've gathered this data by getting a sample size of 1,00 kilograms per day
**kg is the unit used
PARETO CHART
This chart isn't available in your version of Excel.

Editing this shape or saving this workbook into a different file format will permanently break the chart.

Interpretation
For the defect data, the first two bars are the tallest and comprise a large percentage of
all outcomes. The cumulative line chart rises steeply at first and then levels out, indicative of
the Pareto principle in action. The first two categories account for approximately 80% of the
defects.
Collectively, the graph indicates that broken and overcooked chips are the two most
common types of defects. The analysts decide to prioritize reducing these two types first.
FISHBONE DIAGRAM

FINDINGS AND ANALYSIS

Toasted/Overcooked
METHODS
Due to its inconsistent stirring some of the chips were toasted or overcooked as
it was not uniformly cooked side-by-side.
ENVIRONMENT
Too much heat could also be a factor as they are using fire woods and did not
monitor it occasionally. High heat led the chips to deeply fried and burn.
MANPOWER/PERSONNEL
There were only two assigned cooks in three woks/large frying pans. They
manually stir it, but overtime they will get tired resulting into stirring it
inconsistently and slowly.
FINDINGS AND ANALYSIS
Stuck/Undercooked
MANPOWER/PERSONNEL
One of the primary causes why the chips were being stuck it is because after
they sliced it, they directly fry it without separating them.
MATERIALS
Plantains have this texture of viscosity/sticky. Due to its stickiness once they
were undergoing frying, the center of it was not properly cooked well.
But during inspection those stuck and undercooked chips were collected then
manually separated to fry it again.
FINDINGS AND ANALYSIS
Broken Chips
METHODS and ENVIRONMENT
Each crate of chips weights at 10 kilograms. During stacking, each time the stack-
pile goes higher the pressure below increases led the chips to broke.
MANPOWER/PERSONNEL
As the chips are cooked and mixed with the oil using a large pile they collide.
After the chips are cooked from the large frying pan, they need to be placed on a
wide table made of stainless steel to dry. But because of the need for quick
work, sometimes the chips break because of the force as it places on the table.
Same with it misload, while it's inside the crates it's lifted and hit on the ground
by accident so the chips break.
MATERIALS
Overcooked and thinly sliced chips are fragile.
RECOMMENDATIONS
Toasted/Overcooked
• Always check the oil temperature before and during frying.
• Stir consistently.
• Stir in one direction.
• They should use a thermostatically controlled fryer device to control its temperature.
• Hire an additional cook and do hour shifting.
Stuck/Undercooked
• Hire a worker who separates each sliced chip.
• Make sure that the oil is hot enough.

• Add a small amount of cornstarch or flour to the chips.

(This will help to create a barrier between the chips and the oil, making them less likely
to stick together.)

Broken chips
• Stack the crates with minimal weight and height.
• Make each slice thickness uniform.
• Avoid over hitting the chips on the mesh or dryer table.
• Place a rubber floor mat in the stock room.
• Conduct training for employee development and proper handling.