A

Presentation
On
Industrial Training
At
Bikanervala Foods Pvt. Ltd. (Bikano)
Plot no.42, Ecotech-II Udyogvihar Greater Noida.
(03/06/2019 to 03/07/2019)

By:- Priyanshu Kumar Singh

161401032006
Department Of Food Technology,

Institute of Engineering and Technology

Bundelkhand University,
Jhansi, 284128
 About the Company
 Bikanervala Foods Pvt. Ltd. was incorporated on 25thOctober 1988 by Mr. Shyam Sundar Agarwal.

 The company is involved in manufacturing snacks such as :

1. Namkeens.
2. Sweets.
3. Sharbats.
4. Papads. etc. under the brand name of “Bikano”.

 The Company has its 3 manufacturing units at

1. New Delhi,
2. Greater Noida (U.P.) and
3. Rai, Sonipat (Haryana)

 The company also owns and operates as well as franchisees restaurants under the brand name of
“Bikanervala” with 85 outlets in India.
 It also has a global presence with 26 of its outlets operating in:
1. UAE.
2. Nepal.
3. New Zealand.
4. Singapore and USA.
 Company made a hattrick by being declared the Best Sweet Shop of Delhi in 2012, 2013 and 2014
by Times Food Awards.
Vision Of The Company:-
To take across the globe a rich heritage of cuisines founded by our forefathers, with
added flavour, taste, quality and shelf-life, produced & manufactured under hygienic
conditions by adopting latest innovations & technology.
Brand Recognition:-
 Bikano Products are well recognized and known for its Quality and have been awarded ISO 9001:
2015 Certification by UL India Ltd.
 Certification:- ISO 22000:2005.
 List of Products:
S.No. Products

1. Namkeens

2. Snacks

3. Sweets

4. Gift Packs

5. Maida Items

6. Papads

7. Syrups

8. Cookies

9. Winter Delights
  About Greater Noida Factory
 Registered in 2014.
 In GN Factory only varieties of Namkeens are manufactured.
 The Factory is Divided into two Plants one the basis of Product Manufactured.
I. Old Plant (Production of Semi-finished goods, Mixture Namkeens and Bikaneri Bhujia)
II. New Plant (Production of finished goods).
 Plant Manager:- Mr. Upendra Singh.
 Manager HR:- Mr. Ajay Chaubey.
 Packaging Manager:- Mr. Bharat Goswami.
 Production Manager:- Mr. Pankaj Sharma.
 QA Manager:- Mr. Nitin Gupta.
 FSSAI Lic. No. :- 10012051000401
Adress:- Plot no.42, Ecotech-II Udyogvihar Greater Noida, Gautam Buddha Nagar (U.P.)
ISO 22000:2005 Certified Unit
 Several Systems Which Company Follows For Quality and Safety

I. HACCP II. GMP III. 5S System

 Types Of Namkeen
1. Aloo Bhujia 22. Khatta Meetha.
2. All in one. 23. Kurkuri Bhujia.
3. Agra Sev. 24. Laccha Masala.
4. Bhawnagri. 25. Laccha Namak.
5. Badam Lachha. 26. Matar Masala.
6. Bhuja Mix. 27. Moong Dal Masala.
7. Bikaneri Bhujia. 28. Moong Dal Salted.
8. Boondi Pudina. 29. Navratan Mixture.
9. Boondi Salted. 30. Nut Mixture.
10. Diet Bhel. 31. Peanut Salted.
11. Chana Dal Masala. 32. Peanut Hing Jeera.
12. Chana Masala. 33. Peanut Masala.
13. Chana Pataka 34. Peeli Bhujia
14. Chatar Matar. 35. Shahi Mixture.
15. Dal Mixture. 36. Tasty.
16. Dal Mooth.
17. Diet Mixture.
18. Diet Murmura.
19. Kaju Mixture.
20. Kaju Salted Plain.
21. Kashmiri Mixture.
  Packaging
 Packaging is done to the food product for the
specific functions, as packaging plays an
important role in Food Industries.
 Some basic functions of Packaging because of
which it is done the products are:
1. Protection of product from spoilage.
2. Leakage.
3. Breakage, etc.
  Some Basics About Packaging
 Types Of Packaging
I. Primary Packaging(e.g.: Packaging Material) II. Secondary Packaging(e.g.: Dispenser) III. Tertiary Packaging (e.g.:Cartons)
 Types Of Packaging Machine
1. VFFS (Vertical Form Fill and Sealing Machine)

2. HFFS (Horizontal Form Fill and Sealing Machine)

I. Volumetric VFFS

II. Weighmetric VFFS

III. Zipper Type

HFFS (Horizontal Form Fill and Sealing Machine)

 Volumetric Vertical Form Fill and Sealing Machine:
Specification and Applications

 Volumetric Vertical form fill seal packaging (VFFS) machine designed to

package free to fall solid and liquid type products.
 This machine uses volumetric cups for weighing the desired weight.
 The volumetric cups are used according to the volume required.
 Machine Consist of 6 to 8 cups in a circular disc mounted between the hopper
and the collar of the machine.
 Cups of volume 18gm, 20gm, 22gm, 25gm, 40gm, 42gm, 45gm are used.
 Machine is used to pack Small Packets of volume varying from 18gm to 45gm.
 Machine can pack maximum of 140 packets per minute.
 Generally machine is operating at the speed of 80 packets per minute.
 Volumetric Vertical Form Fill and Sealing Machine:
 Weighmetric Vertical Form Fill and Sealing Machine:
Specification and Applications
 Weighmetric Vertical form fill seal packaging (VFFS) machine
designed to package free to fall solid and liquid type products.
 This machine uses weighers at the top of Collar of the machine
for weighing the desired weight.
 Machine consist of 10 to 14 weighers.
 The weighers operates on the principle of permutation and
combinations along with machine has a weight sensor to prevent
errors.
 Machine is used to pack medium size Packets of volume
varying from 50gm to 200gm.
 Machine can pack maximum of 140 packets per minute.
 Generally machine is operating at the speed of 80 packets per
minute.
 Weighmetric Vertical Form Fill and Sealing Machine:
  Packaging Procedure/Laminate
Packaging

Vertical Sealing Lower Horizontal Sealing

Product In Hopper Temp.=(180-200)°C
Temp.= (130-145)°C

Upper Horizontal Sealing Air Filling

& Cutting N₂(Pea Nuts Product) Product In Packet
Temp.=(180-200)°C O ₂(All other Products)
  Zipper Type Packaging Machine

 It is also a weighmetric VFFS type machine.

 Zipper Type Packaging machine designed to package free to
fall solid and products.
 This machine uses weighers at the top of Collar of the
machine for weighing the desired weight.
 Machine consist of 10 to 14 weighers.
 The weighers operates on the principle of permutation and
combinations along with machine has a weight sensor to
prevent errors.
 Machine is used to pack Large size Packets of volume varying
from 200gm to 2000gm(2Kg).
 Machine can pack maximum of 150 packets per minute.
 Generally machine is operating at the speed of 85 packets per
minute.
 Note:- Zipper machine used to package a packets with a zip
at a top of it.
 Laminate/Packaging Material

 Laminate Material is made up of 3 layers.

1. Polyethylene.
2. Metalized Polyethylene Terephthalate.
3. Polyethylene Terephthalate.
 All the layers has their separate purpose of use.
A. To wear Sealing.
B. Used to reduce OTR & WVTR.
 (Oxygen Transmission Rate)
 (Water Vapour Transfer Ratio)
C. Used for ease of Tearing and wear Printing.
  Types of Leakages in Pouches
1. PIS(Product in Seal).
2. Micro leakage.
3. HSW(Horizontal Seal Wrinkle).
4. VSW(Vertical Seal Wrinkle).
5. Pinhole or Body Puncture.
6. Jaw Cut.

Note:- Water bubble test is performed for determining the leakage in pouches.

 Meaning of Batch code at Pouches.

For example: B1AAIF8
 B1 = Company/Plant code.
 A = No. of Shift (A- 1st shift, B- 2nd shift)
 AI = Date of Packaging(A-0, B-1, C-2,…)
 F= Floor no.(F-1st Floor, G-ground Floor)
 8= No. of Machine
  Cartons
 Packaging Material.
 Used as a secondary and sometimes tertiary Packaging
 Makes Transportation easy.
 Reduces the damages in primary packaging.
 Made up of combination of flutes and liners.
 Wavy, layer called “fluting”, which is glued in-between
two smooth sheets called “liners”
 Classification Of Carton’s
1. On the basis of Layers:
 3 layers(2 Liners and 1 Flute)

 5 layers(3 Liners and 2 Flutes)

 7 layers(4 Liners and 3 Flutes)

2. On the basis of Use/Strength:

 Virgin Carton.
 Non-Virgin Carton.
 Quality Testing For Packaging Materials

 For Laminate Materials

1. GSM(Gram per Square Meter)
 To find the mass or density of the laminate.
2. Colour Test.(LAB basis)
3. Sealing Test.
4. Tearing Test.
 For Carton Materials
1. Compression Test
  Production

Old Plant New Plant

Finished Goods Semi Finished Goods/ Finished Goods Semi Finished Goods
Final Product

Aloo Laccha.
Bikaneri Bhujia. Pili Bhujia. Aloo Bhujia.
Agra Sev.
Chana Dal Masala. Agra sev. Moong Dal.
Matar Masala. Bhav Nagri. Tasty.
Chana Ptaka Corn Flakes.
Salted Peanut All in one.
Air India Cashew Khatta Meetha.
Navratan Mix. Etc,
  Production Of Moong Dal
1. Raw Material Inspection. 8. Pass through cooling chamber to reduce temp. to
 Salt % 45°C
 Acidity %  By exhausting out the hot air.

 Alcoholic Acidity % 7. Pass through Flavour applicator.

2. Storage. 8. X-ray Inspection.
3. Sorting and Removing of foreign material. 9. Pass through Metal Detector.
 By sieve shaker with sieve of different size. 10. Packaging.
4. Soaking in water for 3 to 4 hrs. 11. Check for packaging Defects.
 Removal of dust particals. 12. Dispatch.
5. Washing with water for 3 to 4 times .
6. Drain in seiver tank for 6 to 7 hrs.
 To remove excess water.
7. Frying in fryer at 190°C for 90 to 120 sec.
  Production Flow Chart of Moong Dal
Sorting and
Raw Material Removing of foreign
Storage.
Inspection. material

Drying in seiver tank Washing with water Soaking in water for

for 6 to 7 hrs for 3 to 4 times 3 to 4 hrs

Frying in fryer at Pass through cooling

Pass through
190°C for 90 to 120 chamber to reduce
Flavour applicator
sec temp. to 45°C

Pass through Metal

Packaging X-ray Inspection.
Detector.
 Flavour Applicator

Feeder
Fryer With submerdger,
Takeout and Cooling
Chamber
Conveyor from drain
tank

Figure: Fryer With Cooling

Chamber and Flavour applicator
 Important points related to production of Moong Dal

1. Soaking Time = 3 to 4 hrs.

2. Water Drain Time = 6 to 7 hrs.
3. Frying time = 90 to 120 sec.
4. Frying Temperature = 190°C ± 5°C.
5. Cooling Time = 60 sec.
6. Flavouring Time = 80 to 90 sec.
7. Oil used in frying : Palm oil\Rice bran oil.
8. Oil replacement @ 0.3 FFA(Black oil)
9. Fresh Oil : 0.05 FFA
10.Blend oil(Black oil + Fresh oil)
11.Blend oil: 0.13 FFA(Use Till FFA reached 0.5FFA)
  Oil Circulation Within Plant

Fresh Oil Oil in Fryer Till Remove used oil With

FFA = 0.05 FFA = 0.3 FFA = 0.3(Black Oil)

Blend oil tank Refining of oil

Oil in Filtered oil
(Fresh Oil + Filtered oil) Oil in Black oil tank
Tank
FFA= 0.05 FFA= 0.3

Blend oil Blend oil in Fryer

FFA= 0.13 Till FFA = 0.3
  Quality
 Quality plays an important role in food industries as it is an
important factor to develop or improve the food product.
 Quality is a totality of characteristics of food product which
satisfies consumers.
Role of Quality Analysis:
1. To check the various parameters of food products such as:
a) Moisture content.
b) Fat content.
c) Salt content.
d) Acidity % in a food product.
e) Alcoholic Acidity in Raw material.
f) FFA of oil which is being used for frying.
g) Iodine Value of oil.
2. To maintain the quality of products.
3. To produce the product with same taste and texture throughout the
lots produced.
 Testing of Various Quality Parameters
1. Testing of Raw Materials
a) Salt %.
b) Acidity %.
c) Alcoholic Acidity %.
d) Moisture Content.
2. Testing of Finished goods/ Semi-finished goods
a) Salt %.
b) Acidity %.
c) Moisture Content.
3. Testing of oil used
a) Iodine Value.
b) FFA content
c) OV Value
d) PV value
  Testing for Salt %.
Few amount of sample is crushed through mortar and pestle

2g of crushed sample is taken in a beaker.

100 ml of distilled water is added to it.

Shake for 5 min(on Magnetic Stirrer).

Filter with Ordinary or Whattman filter paper No. 42.

Salt% = T*N*58.45/w
10 ml of filtrate is taken in another beaker. T= Titer Value
N= Noramility of Silver Nitrate Solution
W= Weight of sample
10 ml of distilled water is added to it.

Above solution is titrated with 0.1 N Silver Nitrate solution(using 4-5 drops of 5%
potassium chromate solution).

Titer value is recorded at end point when brick red colour appears.
  Testing for Acidity%.
2g of crushed sample is taken in the beaker.

100ml of distilled water is added to the solution.

Shaken for 5 min(on Magnetic Stirrer).

Filter with Ordinary or Whattman filter paper No. 42.

10 ml of filtrate is taken in another beaker.

10 ml of distilled water is added to it.

Solution is titrated with 0.1 NaOH (using 3-4 drops of phenopthalein indicator).

Titer value is recorded at end point, when pink colour appears.

 Testing for % Moisture Content.
Few amount of sample is crushed through mortar and pestle.

Halogen moisture balance is switched on.

Required temperature is set.

5g sample is taken in Halogen Moisture Balance.

Wait for required temperature(40⁰c) and start button is pressed.

Wait for drying of sample till the temperature falls.

Note down the readings.

After sample gets dried, mains are switched off.

  Testing for FFA Content
Take 45ml isopropyl alcohol and add 5ml distilled water.

Neutralize this by using 3-4 drops of phenopthalein indicator.

and titrate with 0.1N NaOH solution.

Pink colour appears.

Add 20g of oil sample.

Heat the solution at 90ºC to check the end point of the oil.

Titrate the solution with 0.1N NaOH by using 3-4 drops of phenopthalein
indicator.

Titrate it till light pink colour appears.

  Testing for IV Value of Oil
Weigh 0.5g of oil sample in Stopper iodine flask.

Add 10ml of carbon tetra chloride.

Add 25ml of Wij’s solution (iodine monochloride).

Store in dark for 30 min.

Add 15ml of freshly prepared 10% KI solution.

Add 50ml of distilled water and mix it well.

Titrate the solution with 0.1 N Sodium thiosulphate (using 4-5 drops of freshly prepared 1%
starch solution after light yellow colour appears)

Titrate it till light pink colour appears.

Conduct the same with blank.

 ThaT’s all
Thank You!
For Your Attention!