2. INTRODUCTION
• Largest Manufacturer’s of Biscuits & Confectionaries almost 80years.
• Parle itself symbolizes quality, nutrition & great taste.
• Most of Parle product are Market Leaders.
• Available Everywhere.
• Beacon of faith & trust for the consumers.
• Great strength is extremely widespread distribution network.
5. • Skim Milk Powder
• Leaving Agents
• Salt
• Emulsifiers
• SMBS
• Flavors
• Citric Acid
• Wheat Flour (Maida)
• Fat (RBD Palm Oil)]
• Sugar
• Invert Sugar Syrup
• Water
INGREDIENTS
Major Minor
6. • Maida– Soft wheat flour is required, as it gives more tender biscuit than hard
wheat flour.
• RBD Palm oil–
Helps in reducing toughness of dough,
Provide sensory (moistness, shortness, crispness & crunchiness)
Protects Flavor
• Sugar– Quantity and Crystal Size of Sugar has big influence on biscuit texture
and dimension. Improves the flavor and makes biscuit hard
• Invert Sugar Syrup– Helps to give color, flavor & decrease crystallization.
• Water– One of important ingredient used in almost all processes.
7. • Skim Milk Powder– To subtle the flavor and textural improvements and to aid
surface colouring.
• Leaving Agents
Ammonia Bi-Carbonate
Sodium Bi-Carbonate
Salt
Emulsifiers
Lecithin or Finamul
Sodium Meta Bi-Sulphate (SMBS)
Flavors
Citric Acid
13. Maida dumping and sifting
Done by 2 methods – Automatic
and Manual
In Automatic, Maida from dosing
tank is transferred to mixer
pneumatically.
In Manual, Maida is transferred
to maida sifter by screw
conveyor and then feeding in
the mixer manually.
Now Automatic system is used
Screw Conveyor
Dosing Tank
14. Sugar grinder
Sugar bags are unloaded &
passed through metal
detectors to remove any
metal particles.
Sugar is transferred to
grinder through screw
conveyor.
Grinded sugar is stored in
Service Tank & from there it
is send to mixer.
Service Tank
15. Pumping of Fat
Fat stored in the Silos is
pumped at a temperature
of 45`c.
Fat is mixed with Lecithin
(an Emulsifying agent).
Mixture of Fat & Lecithin
is added to Liquid vessels
from where it is added to
the mixer for dough
preparation.
Silos
Liquid Vessel
16. Stephan mixer
Material mixed in the
vessels are brought
together in mixer and
stirred for sometime.
After that, the mixture is
passed to Stephan mixer,
where it is mixed by a
speed motor for 1-1.5 mins.
Temperatures specification at
mixing sections
• Water – 15-20`C
• Sugar Syrup – 30`C
• Powder (Sugar + Flour)– 30`C
• RBD Palm Oil – 45-50`C
• Dough Temp. – 28-32`C
Stephan Mixer
17. METAL DETECTOR
• Dough after cutting is
passed through metal
detector, which is just above
dough conveyor; it can
detect all types of metallic
materials.
• Many detectors are placed
through the complete
system for checking of
metal components.
19. OVEN
• 240 feet long oven.
• Consist of 7 chambers.
• 7 chambers are formed of 3 zones.
Puffing Zone
Baking Zone
Coloring Zone
• For baking, LPG or Propane direct gas is fired inside the oven.
• Oven consists of wire band moving inside the oven.
• Temperature set is different in each zone.
20. • Puffing zone (Zone 1 to 3 )
The leavening agents act a major role in this zone. Steam and volatile
gases do rise & increase the volume of the biscuit. This gives a porous
texture by the formation of puffs in the biscuit.
• Baking zone (Zone 4 & 5 )
This is the zone where the biscuits actually get baked. The temperature
of this zone is between 220-320`C. the moisture get evaporated in this
zone and biscuit get baked from inside.
• Coloring zone (Zone 7 & 8 )
This is the zone where the color of the biscuit is attained. The
temperature of this reaction is less than that of the baking zone.
The graph of temperature inside the oven is parabolic i.e. in initial zone temp. is
less, then in middle zone temp. goes to the peak point and in the last zone temp.
reduces again.
Time required to pass through oven is approximately 3mins.
21. Cooling conveyor
It is made up of Convase and
biscuits are cooled naturally
on the conveyor.
Length of the conveyor belt is
350feets.
Metal detectors are placed
just above the conveyors for
detection of any metal
component present in biscuit.
Time required for the flow of
biscuits is approximately 6
mins.
Biscuits move 4 rounds of
cooling conveyor for cooling
23. Packaging consist of three sections
1. Stacking of Biscuits
2. Packaging
3. Dispatch
24. STACKING
• Aligns the biscuits in rows and these rows of biscuits move with
stacker table belt.
• A brush roll is fitted just above the stacker belt to control the
movement of biscuits.
• Operator at he stacker checks the biscuit quality and rejects the
defective.
• These biscuits are sent to packaging machine manually.
25. PACKAGING MACHINE
• Biscuits are packed in various sizes.
• Machines automatically wrap the wrappers
around the biscuits.
• Sealing is done with the roller heaters.
• Some heaters are used for side sealing and
some are used for cross sealing.
• Packaging material used is BOPP (Bioxyl
Oriented Polypropylene).
• After packing the packets are sealed in poly
bags and they are packed into cartoon
boxes, these boxes are sealed and batch
number is printed on them
26. Biscuits packed in boxes are
moved through conveyors and cam
roller belts to the storage room or
the loading of the truck.
Storage of goods is also done
automatically.
27. DISPATCHING
The biscuits packed in a C-boxes are collected on a pallet in the
B.S.R.(Bounded Stock Room) section.
These pallets are carried by a forklift.
These boxes are loaded in truck and transported to various situated at
different locations.
28. • In case of poor finishing or broken or burned out
biscuits, it is kept aside in a different container.
• These biscuits are crushed to powder form again
and are used again.
• 5% of crushed biscuits is used in the new
mixture of biscuits.
• No Wastages.
29. CAPACITY UTILIZATION
• Capacity : 3000 tonnes of Biscuits/month
100 tonnes of Biscuits/day
• Capacity Utilization of 85% Approximately
