HBTBC 380

PRESENTATION
INTERNSHIP REPORT
COMPANY LOCATION

FIGURE 1. National Foods Ltd, Aspindale

ORGANOGRAM

FIGURE 2. Company Organogram

BUSINESS UNITS

 Cereals, Culinary and Baby food Division

 Maize milling Division
COMPANY PRODUCTS

FIGURE 3. Maize mill Division product range

FIGURE 4. Cereals, Culinary and Baby food Division product range

INTERNSHIP OBJECTIVES

 To familiarise with industrial equipment, manufacturing

processes and production.
 To attain hands-on work experience in an industrial
environment.
 To fill in the gap between industry and academia.
 To gain more knowledge about Quality Assurance /Control
systems and techniques.
MANUFACTURING PROCESSES
MILLING PLANT

Hoper

Dirt bin De-stoner Separator Magnet

Conditioning Milling De- Roller

bin germinator mill

Packer Bin Finished Sifter

bin discharger product
bin

Packing
machine

Figure 1 NFL Block Flow Maize Mill Manufacturing Process

CEREALS, CULINARY & BABY FOOD
EXTRUSION PROCESS
 CCB Division comprises of Valuemax plant 1 and Valuemax
plant 2.
 VM1 produces Pearlenta Nutri-active instant maize porridge
which is a fortified porridge and it has four different flavours.
 The flavours include chocolate, Peanut butter, Strawberry and
the original flavour.
 VM2 produces Pearlenta Nutri-Active Instant Cereals like
Cornflakes, Wholegrain Flakes, Bran Flakes, Smooth and
Crunchy Cereal.
VALUEMAX PLANT 1
VALUEMAX PLANT 01

HAMMER EXTRUDER
INTAKE
MILL HOLDING BIN

SECONDARY DRYER EXTRUDER

HAMMER MILL

PREMIX MIXER
SIFTER INTAKE HOLDING BIN

MIXER

FINAL
PACKING PRODUCT
BIN

Figure 1 Instant Porridge Process Flow

VALUEMAX PLANT 2
VALUEMAXPLANT 02

INTAKE MIXER EXTRUDER

CRUMBLER TOASTER FLAKER

Crunchy

Cornflakes

FINAL PRODUCT BIN PACKING

Figure 1 Instant Cereals Process Flow

 Cereal flakes can be made by an extrusion process which
combines mixing, cooking, kneading, shearing and forming.
 Typically, raw materials are fed into an extruder barrel and a screw
conveys the raw materials along the barrel.
 The raw materials undergo heating, compression and mixing to
form a thermoplastic mass.
 The raw materials are then extruded out of the extruder barrel into
strands or ropes, which are cut into pellets.
 The pellets are then dried, flaked with a flaking roller, and toasted.
The toasting process sometimes causes a slight expansion of the
flakes or a curling of the flakes.
 For Crunchy and Smooth Cereal the toasted flakes are passed
through the crumbler and then to the packing bin.
QUALITY ASSURANCE
DEPARTMENT
 Quality Assurance (QA) includes all activities associated with
insuring that measurements are done properly, interpreted
correctly, and reported with appropriate estimates of error and
confidence levels.
 Maintenance of appropriate records of specimen/sample
origins & history (sample-tracking), as well as procedures, raw
data, & results associated with each specimen/samples.
Elements of QA:
 Standard Operating Procedures (SOP's)
 Statistical procedures for data evaluation
 Instrumentation validation
 Reagent/materials certification
 Analyst certification
 Lab facilities certification
 Specimen/Sample tracking
STANDARDS
 The company is aligned with internationally recognized standards in
manufacturing, production & distribution as part of our commitment
to global governance & operational excellence.
 Because global customer’s expectations are constantly evolving,
NFL has aligned with international and industry standards to stay
current with the highest level of Quality, environment, safety and
health, NFL Maize and CCB SBU is certified to:
 ISO 9001:2008 – Quality Management System
 ISO 22000 – Food Safety Management System
 FSSC 22000 – Food Safety Management System
 The QA department makes sure that everything from raw material to
finished product meets quality and safety standards.
 The main tests done are moisture analysis, nutritional content
analysis (mainly fat, fibre, protein and starch), grading of raw
materials and physical inspection.
 The QA department is also responsible for the inspection of
packaging.
 Moisture content can be determined using the following equipment
depending on particle size and quantity of the sample:
i. Near InfraRed spectroscopy
 Near infrared (NIR) spectroscopy is based on the absorption of
electromagnetic (EM) radiation at wavelengths in the range 780 to
2,500 nm.
 The light interacts with the sample and the detector measures its
transmittance and absorbance.
 Transmittance refers to the amount of light that passes completely
through the sample and strikes the detector.
 Absorbance is a measurement of light that is absorbed by the
sample.
 The detector senses the light being transmitted through the
sample and converts this information into a digital number
(NIR,2017). This explains why it is able to detect the amount of
moisture, fat, fibre, protein and starch present in a sample.
 The higher frequency used penetrates deep into samples for
improved results.
 It analyses grains, oilseeds, pulses, beans, lentils, seeds and
more for moisture, Test Weight/Hectolitre Weight, and
temperature (Perten Instruments,2017).
MILL QUALITY CHECKS
Milled maize products shall be:
 Of a natural colour conforming to the colour of the grain from
which it was produced.
 Practically free from foreign matter such as insects, fungi and
dirt.
 Free from fermented musty or other objectionable colours
 Free from rancidity and foreign odours
 Wholesome and fit for human consumption in all aspects
 VM1 Porridge Specifications

VALUEMAX QUALITY CHECKS

TABLE 1. VM1 Porridge Specifications

PARAMETER SPECIFICATION
MOISTURE (%) 8

FAT (%) 2

Organoleptic tests Standard

Density Above 50 g/hl

Weights 1kg (+/-10)

TABLE 2. VM2 Cereals Specifications

PARAMETER SPECIFICATION

MOISTURE (%) 5.5

FAT (%) 4

Organoleptic tests Standard

Density 40max g/hl

Weights 500g (+/-5)

 After analysis the data is recorded and kept in a file.
 If the product is non-conforming the operator/miller is notified
and production is stopped until rectified.
 The QA analyst writes the details of the non-conforming
product and the decision is taken by QA Supervisor and the
responsible person regarding the product.
 The batch of porridge is segregated and held until a decision
is passed.
CONCLUSION

 The internship program was a success as the student gain

experience in the working environment and also gained
practical experience.
 It was observed that, theoretical knowledge acquired during
the course the attaché studies is only a skeleton that needs
practical knowledge acquired at NFL as the flesh for a live and
fully equipped graduate.
REFERENCES
 Near- Infrared Spectroscopy, 2017, How it works Available at:
www.sites.udel.edu [accessed on: 20 June 2020 Available at :
https://www.perten.com/Global/Brochures/AM%205200/AM%2
05200%20brochure%20EN%2020170811.pdf
[accessed on: 07 May 2023]
 Anderson, B. and Almeida, H., 2019, Corn Dry Milling:
Processes, Products and Applications, Elsevier Inc

 Papageorgiou, M. and Skendi, A., 2018, Introduction to cereal

processing and by-products, Elsevier Ltd, Greece
THANK YOU