1
Contents • Aknowledgement • About ‘Parle G Biscuits Pvt. Ltd.’ • Company profile • Products range •
About Biscuits Classification of biscuits Analysis of biscuits
• Brief Description & Uses Of Raw Material • Processing Of Biscuits process manufacturing of glucose biscuits digramatic representation • process Layout Of Parle Biscuits raw material storage mixing unit oven cooling: packing • Intended Use Of ‘Parle G’ Biscuits • Important Details About Raw Materials • Misslanious • Wastages • Specification Of Finished Biscuits • Factors Affecting Processing Of Biscuits
2
• Conclusion
AKNOWLEDGEMENT I express my sincere gratitude towards ‘Mr. S. Panday’ (Manager, parle pantanagar plant) that enables me inside into the biscuit industry and without those support this training experience would not have been possible. I am extremely grateful to ‘Mr .Sanjay Yadav’ (Production Manager) and ‘ Mr. Rohit Gupta’ (quality assurance incharge) for their consistent support and guidance. Also I am grately thankfull to ‘Mr. Shishir’ (HR) and ‘ Mr. Sonu Dhimaan’ (production department) for their help and valuable suggestions. Beside this, I heartly wish to express my sincere thanks to ‘Mr. Manavendra Singh’ (mixing incharge), ‘Mr. Ashok Arya’ (production) and the entire management staff, workers and all employee team of the plant, for their significant contribution towards the completion of the training and without whose support this fantastic and knowledgeful training experience would not have been possible.
Saurabh Kumar Shukla
3
About ‘Parle G Biscuits Pvt. Ltd.’ Company profile The company ‘Parle G Biscuits Pvt. Ltd.’ set up in 1929, the first Indian company to manufacture biscuits and confectionary in the country. Many of parle products , biscuits and confectionary are market leaders in their category. One of its major variety Parle G has been conferred with a prestigious distintion of being the world largest selling biscuits. With a 40% share in the total biscuits market , a large no. of manufacturing units in the biscuits industry, the company enjoys a worldclass reputation and the ‘Parle’ brand symbolizes quality, health and good taste for its products.
Products range The company is associated with the manufacturing of a wide varity of biscuits and confectionary items; • Biscuits: Parle- G ,Atta-G , Magix , Manaco, Krackjack , Hide$Seek Manaco , Fun center , Sixer, Nimkin , Digestive Marie. • Confectionary: Poppins , Melody , Mango Bite , Kismi Toffee Bar ,Chox, Rolacola , Toffee, Orange Candy . Among Parle G Biscuits varieties, parle g and atta g comprises the glucose biscuits. The pantnagar plant location of the company is involved with the manufacturing of the glucose biscuits ‘parle G’ and cream biscuit ‘creams orange.’
4
Introduction about biscuits Biscuits are chemically leavened and baked product made principally from flour, suger and fat. They typically have a moisture content of less than 4% and when packed in moisture proof container has a long shelf life, perhaps 6 month or more. The use of biscuits is more and common in homes due to there ready to eat characteristics. The appeal to the customer is determined by the appearance and the eating quality. They are made in various shape and size and after baking may be coated with chocolate, sandwiched with a fat based filling or other pleasantly flavored additions.
Classification of biscuits a) Depending on texture and hardness ,change in shape of oven the extensibility of dough or various dough is handled prior to biscuit formation. i.
Hard dough biscuit : it has high water and relatively low fat content .the dough is tough and extensible. They exhibit viscoelastic properties similar to bread dough because of the three-dimensional gluten network of flour protein.
ii.
Soft dough biscuit : They contain much less water and relatively high level of fat and sugar. The dough is short and exhibit very low extensible character. Soft dough coheres under pressure but has a short fracture under tension & very little dough development takes place during mixing.
5
b) Sweet In sweet biscuits, the fat and suger level are generally high . The variety provides very short bite, sweet taste and flavor. It is depending of relative proportion of fat and suger. Eg. Glucose biscuits c) Semi-Sweet Semisweet biscuit have a low level of sweetness. The product is hard in texture and low in fat. eg. marie d) Crackers They showing typical type of flaky inner structer formed due to specific processing methaodologies . These can be fermented and non fermented and non fermented type eg. Snacks e) Cookies Cookies product are salty in bite compared to the sweet. They may enriched by incorporation of nuts, dry fruits, chocolate etc. and have high suger and fat in comparison to sweet.
Glucose biscuits These biscuit contain reletively more fat and suger content and fall under the category of sweet biscuits. The suger used mainly in the form of glucose and that’s why it is called glucose biscuits. They form healthy diet and a good source of energy and are economically cheaper than other variety of biscuits. A majority around 65% of the total biscuits manufactured in India are glucose biscuits.
6
Analysis Of Biscuits Glucose Biscuits Weight per biscuit
5.50 gm
Dimention of biscuits
55*36*75
Colour of biscuits
golden brown
pH
6.5 approx
Stack height
7.5 mm
Discription
Biscuits are small baked product made principally from flour, suger, and fat. They have moisture content of less than 2.0% and when packed in moisture proof containers have a long shelf life perhaps 5 months or more. Variety Size Taste Design impression
Specification
Bite Color Weight
Gluco biscuits 56*36*75 Sweet Rectangular
with
0f Parle-g Sime hard Golden brown 88gm for 16 baked biscuits
7
Packet size polybags, Stack heightof
75gm, 100gm, 1kg 2kg jar above 118 –below 122mm 16 biscuits
8
S.N.
Ingridients
Quantity Per Batch
1
Maida
110 kg
2
Suger
33 kg
3
S.M.P.
980 gm
4
Salt
1200gm
5
Soda
350 gm
6
S.M.B.S.
20 gm
7
A.B.C.
900 gm
8
Lecithin
2 liter
9
P.F.M.
195 ml
10
Water
10 kg
11
vanaspati
21.1 kg
12
Invert sugar
11 liter
9
1. Maida It is the ingridient added in the largest ammount in the preperation of biscuit dough. Wheat flour has a unique property to form gluten ( glutenin + gladin). This glutin entrops CO 2 (carbon di oxide) released by leavning agents and get incorporated in dough which escapes during baking. Thus it expends the product. It is principally responsible for structure and texture of biscuits. 2. Suger It gives sweet taste to the biscuits. It is responsible for structer and hardness in short dough biscuits due to crysallization formation. Apart form that it also in colour development due to ceremelization. It also has moisture retaining properties. 3. S.M.P. It provide nutrient to the product and gives liquid media for dough formation. It also add fat, salt, vitamins and some enzymes to the biscuits. It also inhibits the effect of acid. 4. Salt It inhance flavour and sourness of acid. It effects rheology of dough and improve color by action of glutin. Increse in salt concentration length in mixing time. 5. Sodium bi carbonate It is used as a leavening agent. Leavening is a process of incresing the area of dough by creating small sacs of CO2 . It is used to control the acidity of dough. 6. S.M.B.S It is a preservative used in biscuits in very small quantity. It causes gluten to become more extencible and less elastic and therefore reduce the shrinkage of dough pieces during baking .
10
7. A.B.C.(ammonium bi carbonate) It is also used as a leavining agent which discomposes complete when heated, breakning down.
8. Lecithin It is an extract from soy and act as an emulsifier used for binding of fat and water molecole. It improve moisture retention and it effect at very low concentration and does not allow to seperation of water and fat during baking , Thereby preventing the crust formation. 9. P.F.M. it gives parle g ,it gives cheracterstic flavour and aroma. 10.Fat / Vanaspati it forms a layer over the flour particles product a tender texture to the finished product . it mains function is shorten to gluten strength and allow greater expentionof product during proffingit works as atenderising agent ,during mixing it intraps air to theincorporation of other ingradients to finished productduring baking it become melt and release air bubbles which contribute to the leavining actionof baking powder and expend the steam .melted shortening are deposited around the cell wall of coagulating structure to provide a tenderize effect and lubericate the texture .it also prevents hardening of biscuit during and after baking . 11.Invert Suger it made by the hydrolysis of sucroose to glucose and fructose .the process is known as invertionit prevents thecrystelisation of suger and resistant to microbiol spoilage due to its low water activity.it also helps in moisture retention .at high temprature ,it easily undergoes browning reaction. Thus giving color and flavour to the biscuits.
================================
Processing of Biscuits
11
Processing of the biscuit involve these steps1. 2. 3. 4. 5.
Mixing of raw materials Rotary molding of dough Baking process in oven Cooling of biscuits Packeging and storage
Process manufacturing of glucose biscuits Handling & material of ingridients Mixing of the ingredients Rotary molding of biscuits Baking of biscuits Cooling Packaging & Storage
PROCESSING OF BISCUITS {digramatic representation}
12 Suger
flour
l.marvo
water
sddduger
Mixer ( all the raw materials mixed here) Mixed product known as dough
Send to rotary
syrup
marvo
13
Rotary
oven Cooling conveyor Stacker Packaging Ready to Eat
PROCESS LAYOUT OF PARLE BISCUITS
14
Procedure:First of all Plants of Parle Biscuits Pvt. Ltd buys raw materials from the various suppliers and stored them into the store room. These raw materials are then sent to laboratory for testing and after testing only then these are used for manufacturing Parle G biscuits. For the production of Parle G Biscuits the whole plant consists of different units to perform various works. Parle Biscuit plant is divided into different sections, they are as follows:1. Raw Material Storage 2. Maida Sugar Section 3. Mixing Unit 4. Rotary Unit 5. Oven 6. Packing Unit
Raw Material Storage:Each industrial plant should have an area for raw material storage. In these storage areas, the raw materials are kept until they are used for the production of desired finish product. For the production of Parle-G Biscuits a variety of raw materials are required such as Maida, Sugar, Sugar Syrup, Vanaspati (Ghee), etc. In Maida Sugar Section, both Maida and sugar are stored in large vertical tank. RBD (Vanaspati) is stored in vertical silo. These storage areas should be free from moisture, water logging, direct sun light, insects, and rodents, so to keep the material safe before it is used.
Mixing Unit:-
15
In the production of biscuits this Mixing unit is most important part of total production area. This unit consists of various vessels or mixers to perform mixing work in a measurable way for different ingredients used in biscuits production:• • • •
POWDER VESSEL LIQUID VESSEL CREAM VESSEL STEPHEN MIXER
1. POWDER VESSEL:Powder vessel receives Maida from Maida Service tank through pipelines. This vessel receives 110 kg of Maida per batch. Moisture content in Maida is about 13% (12±1). 2.
CREAMER VESSEL:-
Creamer vessel receives three ingredient i.e. Ghee, Powered Sugar, Solid Milk powdered. 20.900kg Ghee per batch is supplied to vessel from RBD silo through pipelines at a temperature of about 49ºC. Powdered sugar of about 33kg per batch is supplied to vessel through Powdered Sugar Services tank and thirdly SMP 950gm is provided manually to the creamer vessel. Finamul is used as an emulsifier which is mixed with Ghee. In 800kg of Ghee, 2.490kg Finamul is mixed. Particularly in each batch 0.065kg Finamul is added with 20.900kg of Ghee. Finamul is directly supplied through pipeline with ghee to the creamer vessel. CV Agitator is attached to the vessel to agitate the ingredients properly. 3. LIQUID VESSEL:-
Liquid vessel receives SSA (Soda +Salt+ Ammonia), Sugar Syrup, PFM (Parle Flavor Mix), and water. 2.5kg of SSA is provided manually to vessel. About 11kg of sugar syrup and 11kg of water is supplied to the vessel through pipelines. Only 190ml of PFM is used in a single batch. Temperature of sugar syrup should be about 42ºC and for water temperature should be 2.6ºC during summer time. Color of sugar syrup is Golden Brown. BRIX for sugar syrup is about 75 – 80 and pH is about 2.9.
16 LV Agitator is attached to vessel to agitate the ingredients properly. The amount of SSA should be in such a way that 300gm soda + 1200gm ammonia + 650gm salt is to be taken per batch. Ammonia is used for puffing of biscuits during baking and to maintain the stack height of biscuits. If the amount of ammonia is more than the stack height will increase and vice versa. Another Paste preparation machine is also fixed at mixing site to make RB paste of Reprocessed Biscuit. This RB Paste is also mixed in dough with 7kg per batch. Sigma mixer is used in to prepare paste. In Parle plant the total weight of single batch is about 204kg. It may vary from 202kg to 205kg per batch.
STEPHEN MIXER The Stephan TK Mixer is an ideal component to fully automatically feed the down-stream make-up equipment for biscuits. After receiving the different ingredients from three vessels it works to mix them in proper way. There are two types of motor attach to it to mix all materials properly. One is Baffle motor and other is Mixer motor. Baffle motor rotates in two directional motion one is clockwise direction during discharge of mixture to the hopper and another is in anticlockwise direction during mixing. Rotation round in Stephen Mixer is about 600 to 700 revolutions. Quality improvement and automatic batching are the main advantages of the Stephan Mixer. Biscuits and rolls will have bigger volumes, more uniform texture and a more tender and delicate crumb. High volume output results from the short kneading time and fast ingredient charging 1000 kg/h to 6000 kg/h depending on the model. In a few seconds, all ingredients are homogeneously mixed. When all material is mixed properly mixture is discharged in the hopper which is a part of rotary section. Brine solution is used around the Stephen Mixer to make the temperature cool about -15ºC.
The operation can be divided into four phases:-- loading, mixing, kneading and discharging. After loading the mixer wi th all ingredients, the mixing starts. The unique shape of the mixing/kneading tool, combined with the mixing baffle, produces a very homogeneous mix. The combination of the mixing tool allows for the optimum hydration of the flour. Due to this intensive hydration, a higher yield is possible in the range of 1.5-3% depending on the type of dough. This complete development leads to a delicate crumb and an extremely machine able dough. Using a special attachment, the Stephan Mixer can knead the dough’s under a vacuum, if it is desired to have a super fine pore structure like American or English white pan bread
STEPHAN MIXER
17
Rotary:Rotary hopper has rotary blades to rotates and mix it finally as the final dough is formed. Dough temperature is about 33.5ºC. Roller rolls the dough and cutting knife help in cutting the dough in spreaded form so that dough should pass from roller die equivalently and each cup of die receives appropriate amount of dough to form biscuits. Rubber roll provide a pressure to dough of 2.5kg for better shape of biscuits in die. Rubber lined anvil roller is adjustable in height so that pressure can be controlled at both sides in parallel or independently. The anvil roll is being driven by friction of the cutting web, which is independently powered by its own separate drive. For safety reasons the cutting roll is provided with guard, removal of which stops the motor. Roller Die drum has 12 cups in circle and 31cups in length of the die drum. Die give the shape and size to biscuits and also imprint the name of product on biscuit i.e. Parle G on the top side of biscuits. After this biscuits are passed on to rotary belt. Then these biscuits are conveyed up to oven and these biscuits are passed on the wire band belt fin oven.
18
Biscuits At Wirement After Rotary
OVEN:The oven body consists of steel steam tight tunnel with equally divided zones of the radiators. Stainless steel expansion joints are provided between these zones in order to eliminate the expansion of the oven section. The inspection doors are provided for inspection of the baking goods during the process. Length of oven is 324 feet from drum to drum. The complete chamber is insulated with heat proof wall from outside to conserve heat and increase efficiency. This insulated chamber reduces the chance of heat loss into the surrounding atmosphere .The fully automatic imported burner shall be fitted to the chamber and the temperature shall be controlled by automatic temperature controller on the control panel. The complete oven will be covered with 10" thick mineral wool insulation from top, bottom and the sides. The bottom portion of the oven at the sides will be covered with CRC sheets for the conveyor protection and to avoid heat loss. In oven total numbers of burners are 333. There are three types of burners:
1. Balancing burners 2. Non Balancing burners
= =
125 in number 190 in number
19
3. Preheating burners
=
18 in number
Preheating burners works as to heat the wire band which is going in the reverse direction toward the rotary. Total length of oven is divided in three zones i.e. first 30% length of oven is known as puffing zone, middle 40% length of oven is known as baking zone and last 30% length is known as coloring zone. Temperatures in the oven is in parabolic range during starting and end three zones temperature will be less and in middle four zones, the temperature will be high up to 320±20ºC.
Oven Temperature Range:-
At RPM – 32 :-
Zone 1 Upper
Zone 2
Zone 3
Zone 4
Zone 5
Zone 6
Zone 7
Zone 8
Zone 9
220±20 240±20 260±20 280±20 290±20 300±20 275±20 245±20 240±2 0
Zone 10 220±20
Bottom 200±20 230±20 250±20 270±20 285±20 290±20 250±20 230±20 235±20 190±20
20
There are damper plates at each zone of oven whose opening and closing maintain the steam inside the oven. During first three zones damper plates are 20% to 30% open, so as to maintain the steam in oven for better puffing of biscuits. In zones no. 4, 5, 6 & 7 the damper plate is open about 40% to 60% at this level biscuits are baked and temperature of these is also high. And last three zones i.e. 8, 9 & 10 the damper plates is almost totally opened to released all steam from the oven. Last three zones are known as coloring zone. Zones no. 6, 7 & 8 is known as CCP zone (Critical Control Point). Minimum temperature of CCP zone is 230ºC to 320ºC.These zones helps in controlling the moisture of biscuits and also increase the shelf life of the finished product. This CCP zone is most important zone among all other zones because it maintains the shelf life of the biscuits. CCP should be monitored time to time to ensure that this zone is receiving the desired temperature range or not. When biscuits are fully baked at the 10 th zone they are released on the cooling conveying belt for better cooling of hot baked biscuit. Color of fully baked biscuit is Golden Brown.
Cooling:The hot baked biscuits from oven are conveyed through cooling conveying belt for cooling of biscuits. The total travel of the cooling conveyor is 1.5 times of the oven length. The biscuit continues to run on it for 5 to 7 minutes so that the biscuits become cool and all the moisture that biscuits contain gets evaporated. And because of the above reason the factory has “S FLOW LAYOUT” in the factory. A metal detector is placed after cooling when biscuits move towards packing so that to ensure that the biscuit is free from any metallic contamination. This will help in reducing the chance of contamination in biscuits.
Packing:The conveyor continues to move to counting table where biscuits are counted and seen that it is going on properly or not. The conveyor continues till the biscuits reach the STALKING TABLE at which the biscuits are packed in very orderly manner. From cooling conveyor sum biscuits are diverted through AUTO FEEDING MACHINE to another stalking machine where packing is done. In auto feeder machine has inline pusher having 6 shots and cross pusher. Cross pusher maintain the counting of biscuits such as 16 biscuits in one packet.
21
Particularly stack height of biscuits is also check at this level. The stack height of 16 biscuits is 122mm.Weight of 16 biscuits at rotary is 104gm. Weight of 4 biscuits after coming out from oven is 22.4gm. Stack height should be checked every one hour to maintain the profit of company, because if stack height will increase then profit will reduce. Stack height is monitored by regulating the amount of Ammonia & Water during mixing. Auto Feeder machine has a control panel to control cross pusher. From stalking table the biscuits are moved on conveyor to MULTI PACK WRAPPING MACHINE were 16 biscuits are packed into a regular Parle G wrapper so that the weight of 16 biscuits comes up to 120±2 grams. Machine speed is about 132-135 PPM. Plant runs on 35 RPM. On increasing 1 RPM then 3.5 PPM will increase. During sealing of packet the temperature of UJ (Upper Jaw) is 138ºC and LJ (Lower Jaw) 139ºC. There are two roller sealers i.e. RL1 & RL2 for bottom sealing. Temperature of RL1 is 202ºC and RL2 is 205ºC. When 16 biscuits are packed in plastic wrapper these packets are conveyed in forward direction.Then 24 packets of Parle G biscuits are packed into a POLY BAG. And after packing it into poly bag it is sent to SEALING MACHINE where it is sealed, then it is sent to CORRUGATE BOX SECTION in which 6 poly bags are placed manually and box is conveyed for final sealing.
TAPPING MACHINE:-
22
Six such poly bags are placed in one such corrugated box and the box is passed through the tapping machine where the boxes are tapped and labeling of date, batch no. and other detail is also done at this tapping machine, then these are sent through a long diversion conveyer belt. This belt helps to transfer the box to the dispatch section directly. 36 boxes are arranged on pallet in the dispatch section, from where they are transferred to the various dealers all over the India and worldwide
Intended Use Of ‘parle G’ biscuits… Where it is sold..??
Who will consume.?
Sensitive consumer
Directly to the consumers of India and abroad. People of all age group except below one year infants.
Glutin Allergic, Diebitic Person, Infants below 01 year.
Some Important Details about…
23
Raw Materials:Maida Moisture Sedimentation value Glutein percentage Alcoholic acidity Total ash Acid insoluble ash
13% (12±1) 18-23ml 8%-10% W.B.- 0.62 & D.B.- 0.65 1% 0.04%
RBD PV (Peroxide value) Free Fatty acid Iodine value Moisture percentage Melting Point
1.25meq/kg 0.1 %( max.) 45-56 0.1% 35ºC to 37ºC
S.M.P. Moisture percentage Total ash Protein
4% 8.2% 34%
MISSLANIOUS
24
Reasons for increasing Stack Height:There are various factors due to which the stack height of biscuits will increase. Following are the reasons which increase stack height: 1) Dough Quality •
Quantity of Ghee is less.
•
Quantity of sugar is less.
•
Dough temperature is more.
•
Increase in amount of Ammonia.
2) Molding •
More weight of biscuit.
•
Pressure due to Roller is less.
3) Baking •
Damper position.
•
Proofing zone has high temperature.
Reason for increase in length of Biscuit:1) Dough Quality •
Moisture content of dough is less.
•
Amount of sugar is less.
25 •
Amount of Ghee is less.
•
Mixing time is more.
•
Reprocess able dough is more.
2) Baking •
Distance between two biscuits is more on wire band.
3) Rotary •
Speed of Rubber Roll is more.
•
Standing time at proofing zone is more.
Reasons for increase in width of Biscuits:1) Dough Quality •
Consistency of dough is not proper.
•
Amount of Ghee is more.
•
Amount of sugar is more.
•
Particle size of sugar is small.
•
Particle size of Maida is small.
2) Mixing •
Mixing time is less.
•
Improper temperature of dough.
3) Baking
26 •
Bottom temperature is less.
•
Mostly damper plates are closed.
•
Temperature of 1st zone is less.
4) Molding •
Weight of biscuits is more.
•
Excessive pressure of Rubber Roll.
WASTAGES:If an industry produces some products on a large scale then there is also a chance of wastage of raw material or any other material used in production. There are various types of wastage in production of biscuits. Wastages includes like wastage of ingredients used in production, dropping wastage, wrapper, corrugated box and such other. During mixing the wastage of raw material are as follows:
List of Raw Materials Maida Sugar
Wastage (in gm) per shift 240- 280 200-250
27
Paste SMBS ABC
300 25 1020
Same as during packing there is dropping wastage i.e. dropping of biscuits or damaging of biscuits which is about 15kg to 30kg per machine per shift. These biscuits are further reprocessed and known as RB Paste. During packing of biscuits in packing area there is wastage of wrapper at each packing machine is about 300gm – 450gm wrapper per shift. It may vary from machine to machine. If there is any technical problem related in packing machine then this value may varies. At last there is a chance of wastage of corrugated box in which 6 poly bags are packed. Wastage of corrugated box is about 20 boxes to 30 boxes per shift.
Specification of finished biscuits ph Moisture Ash Fat Acidity of extracted fat
6.8-7.0 less than 2.0% 1.5 (max.) 13.0(min) 1.0 (max)
Specification of biscuits shelf life study
28
S.N
Date
Moistur e
1
07-06-2010
1.81
2
08-06-2010
3
Fat
Taste
Smell
12.89
OK
OK
1.85
12.75
OK
OK
09-06-2010
1.90
12.98
OK
OK
4
10-06-2010
1.83
12.97
OK
OK
5
11-06-2010
1.85
12.85
OK
OK
Factors affecting Processing of Biscuits The major factor governing the eating chacterstics of glucose biscuits is the consistency of dough formed as a result of mixing. The nature of viscoelastic properties of dough mainly governs the texture, spread, color and bite of the resulting biscuits. This depends upon nature of the flour,and its glutin forming chacterstics. More extensible or less elastic dough is desired during biscuit manufacturing. Sometimes improper mixing of fat and water in the batch results in excess glutin formation ,as te flour is more in contact of water. This causes the dough to become less extewnsible or more elastic leading to improper spread and texture of the biscuit. This can be overcome
29
by ‘creaming ’ of fat using emulsifier (eg. Lecithin or finamul) and then mixing with water so that it vforms a good emulsion of both. This causes the dispersion of fat evenly thoughout the dough and limits the formation of glutin. Sugers, depending upon the leveland type effect therheological chariostics of the dough . increasing the suger content reduces the extrusion time, dough consistency, biaxial extensional viscosity and increases the spread. Development of glutin is also reduced and there is an improvement in the texture of biscuits. Incorporation of additional reducing suger, particularly liquid glucoseee and syrup limits glutin formation and produces changes the adhesiveness and stickiness of the dough. The mixing time as well as the standing time of the dough also affects its characterics.if the dough after mixing is allowed to stand for a longer period, glutin formation enhances and the dough become harder. The content of leavening agent in the dough as well as condition of temperature and pressure inside the oven influence the baking characterstics to a great extent . biscuits baked under reduced paper than the normal have better textural profiles . The control of moisture in the biscuit is critical to insure its greater shelf life and microbiological safety as spoilage accelerates in presence pf high moisture content .as soon as the biscuit cools,it must be paked in minimum possible time so that it does not absorb moisture from the surrounding atmosphere . Emulsification improves the ablity of the protein film to entrap air in the batter duringcreaming or mixing .thus the biscuit opn outmore
30
during the biscuit,thus improving the palatability .the biscuit made byusing emulsifier have more crispness. Colour of the biscuits is due to• Mallard reaction • Ceremelization of suger Time requires to bake the biscuits in oven is generally 3-4 min.Baking time depend on rpm of die and rotary. Higher the RPM, lower will be the baking time & vice versa. Generally one dough batch servives upto 15 min and nearly 20 batches are served per hour, depends on RPM of rotary & staker. CCP for physical hazards [Metal] is checked at rotary as well as cooling conveyor for which metal detector is placed. CCP for metal detector is: • For ferrous = 1.5 mm • For non-ferous = 2.0 mm • For S.S. = 2.5 mm
Conclusion
The Pantnagar plant location of the company involved with he manufacturing the glucose biscuit Parle-G . Generaly biscuits are small chemically leavened baked product made principally form flour suger and
31
fat .their glucose biscuit contain relatively more fat and sugar content and fall under the category of sweet biscuit .The sugar used is mainly in the form of glucose and hence it is called glucose biscuit .They form a health diet and a good source of energy as well as re economically cheaper than another vareity of biscuit around 65% of total biscuit manufactured in india are glucose biscuits. Some time defects lie cracking choking, excessive spreading perishin can detected in the biscuits but these problems hence relevant remedies. The elasticity of dough mainly governs the texture, color and bite of resulting biscuits.The in turn depend on the nature of the flour and its glutin forming characteristics. A less elestic and more extensible dough is desirable during biscuit making. Suger depending on the level and type effect the rheological characterstics of the dough . development of glutin is also redused and there is improvement in the texture of biscuits. The mixing time as well as standing time of the dough also affects . Its characterstics gluten formation enhance and dough become harder condition of temprature and pressure inside the oven influence the baking charecterstic to a great extent the control of moisture in the biscuit is critical to insure it greater shell life and microbiological safety . As soon as the biscuit is cooked it must be packed in minimum possible time so that it does not absorb moisture from the sorrounding atmosphere. *=================*
