Parle products, all about manufacturing by Manpreet singh Digital
Project on: Parle Glucose
Submitted by: Manpreet Singh
Email : firstname.lastname@example.org
Submitted to: Sunil Malhotra
PARLE BISCUIT STORY
THE STRENGHT OF BRAND
THE QUALITY COMMITENT
THE MARKETING STRENGTH
THE CUSTOMER CONFIDENCE
PARLE G - THE EVOLUTION!!!
IMPORT - EXPORT
VARIOUS UNIT OF COMPANY
IMPORTANT PEOPLE’S OF THE COMPANY
HIERARCHY OF PARLE PRODUCTS
MANUFACTURING PROCESS FLOW CHART
PROCESS LAYOUT ( FLOW )
PROCESS LAYOUT ( DESCRIPTION )
BISCUIT BAKING OVEN
MULTIPACK WRAPPING MACHINE
MACHINERY USED IN MAINTANCE OF MAJOR MACHINERY
USE OF COST CUTTING MEASURES
A long time ago, when the British ruled India, a small factory was set up in the suburbs of
Mumbai city, to manufacture sweets and toffees. The year was 1929 and the market was
dominated by famous international brands that were imported freely. Despite the odds
and unequal competition, this company called Parle Products, survived and succeeded, by
adhering to high quality and improvising from time to time.
A decade later, in 1939, Parle Products began manufacturing biscuits, in addition to
sweets and toffees. Having already established a reputation for quality, the Parle brand
name grew in strength with this diversification. Parle Glucose and Parle Monaco were the
first brands of biscuits to be introduced, which later went on to become leading names for
great taste and quality.
HOW PARLE FOUGHT TO MAKE BISCUIT AFFORDABLE TO ALL
Biscuits were very much a luxury food in India, when Parle began production in 1939.
Apart from Glucose and Monaco biscuits, Parle did offer a wide variety of brands.
However, during the Second World War, all domestic biscuit production was diverted to
assist the Indian soldiers in India and the Far East. Apart from this, the shortage of wheat
in those days, made Parle decide to concentrate on the more popular brands, so that
people could enjoy the price benefits.
Thankfully today, there's no dearth of ingredients and the demand for more premium
brands is on the rise. That's why; they now have a wide range of biscuits and
mouthwatering confectionaries to offer.
THE STRENGTH OF THE BRAND
Over the years, Parle has grown to become a multi-million US Dollar company. Many of
the Parle products - biscuits or confectionaries, are market leaders in their category and
have won acclaim at the Monde Selection, since 1971.
Today, Parle enjoys a 40% share of the total biscuit market and a 15% share of the total
confectionary market, in India. The Parle Biscuit brands, such as, Parle-G, Monaco and
Krackjack and confectionery brands, such as, Melody, Poppins, Mangobite and Kismi,
enjoy a strong imagery and appeal amongst consumers.
Be it a big city or a remote village of India, the Parle name symbolizes quality, health and
great taste! And yet, we know that this reputation has been built, by constantly innovating
and catering to new tastes. This can be seen by the success of new brands, such as, Hide
& Seek, or the single twist wrapping of Mango bite.
In this way, by concentrating on consumer tastes and preferences and emphasizing
Research & Development, the Parle brand grows from strength to strength.
THE QUALITY COMMITMENT
Parle Products has one factory at Mumbai that manufactures biscuits & confectioneries
while another factory at Bahadurgarh, in Haryana manufactures biscuits. Apart from this,
Parle has manufacturing facilities at Neemrana, in Rajasthan and at Bangalore in
Karnataka. The factories at Bahadurgarh and Neemrana are the largest such
manufacturing facilites in India. Parle Products also has 14 manufacturing units for
biscuits & 5 manufacturing units for confectioneries, on contract.
All these factories are located at strategic locations, so as to ensure a constant output &
easy distribution. Each factory has state-of-the-art machinery with automatic printing &
All Parle products are manufactured under the most hygienic conditions. Great care is
exercised in the selection & quality control of raw materials, packaging materials & rigid
quality standards are ensured at every stage of the manufacturing process. Every batch of
biscuits & confectioneries are thoroughly checked by expert staff, using the most modern
THE MARKETING STRENGTH
The extensive distribution network, built over the years, is a major strength for Parle
Products. Parle biscuits & sweets are available to consumers, even in the most remote
places and in the smallest of villages with a population of just 500.
Parle has nearly 1,500 wholesalers, catering to 4,25,000 retail outlets directly or
indirectly. A two hundred strong dedicated field force services these wholesalers &
retailers. Additionally, there are 31 depots and C&F agents supplying goods to the wide
The Parle marketing philosophy emphasizes catering to the masses. They constantly
endeavour at designing products that provide nutrition & fun to the common man. Most
Parle offerings are in the low & mid-range price segments. This is based on their
understanding of the Indian consumer psyche. The value-for-money positioning helps
generate large sales volumes for the products.
However, Parle Products also manufactures a variety of premium products for the upmarket, urban consumers. And in this way, caters a range of products to a variety of
THE CUSTOMER CONFIDENCE
The Parle name conjures up fond memories across the length and breadth of the country.
After all, since 1929, the people of India have been growing up on Parle biscuits &
Today, the Parle brands have found their way into the hearts and homes of people all over
India & abroad. Parle Biscuits and confectioneries, continue to spread happiness & joy
among people of all ages.
The consumer is the focus of all activities at Parle. Maximizing value to consumers and
forging enduring customer relationships are the core endeavours at Parle.
Their efforts are driven towards maximizing customer satisfaction and this is in synergy
with their quality pledge. " Parle Products Limited will strive to provide consistently
nutritious & quality food products to meet consumers' satisfaction by using quality
materials and by adopting appropriate processes. To facilitate the above we will strive to
continuously train our employees and to provide them an open and participative
PARLE G - THE EVOLUTION !!!
Parle-G has been a strong household name across India. The great taste, high nutrition,
and the international quality, makes Parle-G a winner. No wonder, it's the undisputed
leader in the biscuit category for decades. Parle-G is consumed by people of all ages,
from the rich to the poor, living in cities & in villages. While some have it for breakfast,
for others it is a complete wholesome meal. For some it's the best accompaniment for
chai, while for some it's a way of getting charged whenever they are low on energy.
Because of this, Parle-G is the world's largest selling brand of biscuits.
Launched in the year 1939, it was one of the first brands of Parle Products. It was called
Parle Gluco Biscuits mainly to cue that it was a glucose biscuit. It was manufactured at
the Mumbai factory, Vile Parle and sold in units of half and quarter pound packs.
The incredible demand led Parle to introduce the brand in special branded packs and in
larger festive tin packs. By the year 1949, Parle Gluco biscuits were available not just in
Mumbai but also across the state. It was also sold in parts of North India. By the early
50s, over 150 tones of biscuits were produced in the Mumbai factory. Looking at the
success of Parle-G, a lot of other me-too brands were introduced in the market. And these
brands had names that were similar to Parle Gluco Biscuits so that if not by anything else,
the consumer would err in picking the brand. This forced Parle to change the name from
Parle Gluco Biscuits to Parle-G.
Originally packed in the wax paper pack, today it is available in a contemporary,
premium BOPP pack with attractive side fins. The new airtight pack helps to keep the
biscuits fresh and tastier for a longer period.
Parle-G was the only biscuit brand that was always in short supply. It was heading
towards becoming an all-time great brand of biscuit. Parle-G started being advertised in
the 80's. It was advertised mainly through press ads. The communication spoke about the
basic benefits of energy and nutrition. In 1989, Parle-G released its Dadaji commercial,
which went on to become one of the most popular commercials for Parle-G. The
commercial was run for a period of 6 years.
Parle-G grew bigger by the minute. Be it the packs sold, the areas covered or the number
of consumers. It became a part of the daily lives of many Indians. It wasn't a biscuit any
more. It had become an icon. The next level of communication associated the brand with
the positive values of life like honesty, sharing and caring.
In the year 1997, Parle-G sponsored the tele-serial of the Indian superhero, Shaktimaan
that went on to become a huge success. The personality of the superhero matched the
overall superb benefits of the brand. Parle extended this association with Shaktimaan and
gave away a lot of merchandise of Shaktimaan, which was supported by POS and press
communication. The children just could not get enough of Parle-G and Shaktimaan.
In the year 2002, it was decided to bring the brand closer to the child who is a major
consumer. A national level promo - `Parle-G Mera Sapna Sach Hoga' was run for a
period of 6 months. The promo was all about fulfilling the dreams of children. There
were over 5 lakh responses and of that, over 300 dreams were fulfilled.
Dreams that were fulfilled ranged from trips to Disneyland at Paris & Singapore; free
ride on a chartered plane; 20 scholarships worth Rs 50,000; a special cricket coaching etc.
The year 2002 will go down as a special year in Parle-G's advertising history. A year that
saw the birth of G-Man - a new ambassador for Parle-G. Not just a hero but also a superhero that saves the entire world, especially children from all the evil forces. A campaign
that is not just new to the audiences but one that involves a completely new way of
execution that is loved by children all over the world – Animation
To make the brand much more interesting and exciting with children, it was decided to
launch a premium version of Parle-G called Parle-G Magix in the year 2002. Parle-G
Magix is available in two exciting tastes - ‘Cocoh’ and ‘Cashew’. The year 2002 also
witnessed the launch of Parle-G Milk Shakti, which has the nourishing combination of
milk and honey, especially launched for the southern market.
Parle-G continues to climb the stairs of success. Take a look at the global market where
it is being exported. First came the Middle East then USA followed by Africa and then
Australia. An Indian brand, that's exported to almost all parts of the world. After all that's
what you would expect from the Parle-G World's Largest Selling Biscuit.
IMPORT - EXPORT
The immense popularity of Parle products in India was always a challenge to their
production capacity. Now, using more modern techniques for capacity expansion, we
have begun spreading their wings and are going global.
Parle bisuits and confectionaries are fast gaining acceptance in international markets,
such as, Abu Dhabi, Africa, Dubai, South America and Sri Lanka.
Even the more sophisticated markets like USA & Australia, now relish Parle products.
As part of the efforts towards a larger share of the global market, Parle has initiated the
process of getting ISO 9000 certification. Many Parle Products have also won Gold,
silver and bronze medals at the Monde Selection.
VARIOUS UNIT OF COMPANY
There are five mother units and thirty one contact manufacturing units in India. The main
difference between mother units and contact units is that mother units produce more than
one product that is PARLE G, MONACO, KRACK JACK, SIXER, HIDE AND SEEK
etc. while contact unit manufacture only PARLE G.
Mother units are as follows.
Banglore and Kolkata
IMPORTANT PEOPLE OF THE COMPANY
MR. VIJAY CHAUVAN
MR. ANUP CHAUVAN
MR. AJAY CHAUVAN
MR. RAJESH RAUL
HIERARCHY OF PARLE PRODUCTS
MANUFACTURING PROCESS FLOW CHART
RAW MATERIAL TESTING
PROCESS LAYOUT OF PARLE PRODUCTS LTD.
PARLE G are made at parle products ltd. at vile parle .
First of all the parle products buys RAW MATERIAL from the various suppliers and
stored into the store room. This raw material is then sent to laboratory for testing and
after testing only it is used for manufacturing. The raw material consist of Wheat flour,
Sugar, Partially hydrogenated edible vegetable oils, Invert syrup, Leavening agents (503
Baking powder) Milk, solids Salt Emulsifiers (E 322 or E 471 or E 481) and Dough
conditioners (E 223).
Such a mixture of raw material is taken and mixed into STEPHAN MIXTURE, which is
high power mixture machine. Specially made for mixture of dough, from which the
mixture is passed to molder called ROTARY MOULDER. Through that moulder
approximately 10,000 come out in a minute. Moulder had 260 cups fitted in it which
gives shape to the biscuits and an impression embossed on it of parle-g.
From rotary moulder the dough is passed through a 260 feet long OVEN which is
approximately 340* c. In oven there are three stages to be followed
Removal of moisture.
Building the structure of biscuits.
Colourings of biscuits take place.
From oven the hot biscuits are placed on the COOLING CONVYOR, which is 260 feet
long and the biscuits 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.
The conveyor continues to move to COUNTING UNIT 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.
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 100 grams.
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 and
Then the boxes are kept on conveyor and sent to DISPATCH SECTION from were the
biscuits are sent to various places in India and all over the world.
Partially hydrogenated edible vegetable oils
Leavening agents (503 Baking powder)
Emulsifiers (E 322 or E 471 or E 481) and
Dough conditioners (E 223) and contains added flavours.
The raw material is mixed in certain proportion, to get the best quality of biscuits. All the
ingredients are tested in laboratory so that no low quality of raw material is used in
manufacturing process. The raw material is tested for their acidic value, moisture it
contains, and quality of milk powder.
The inventory of the company that is the raw material is of a week. They store such
inventory in store room and then is sent for testing in laboratory and after testing it is sent
There is nearly 10,000 employees working in the company and are working in three
shifts.35,000 tones of biscuits are manufactured in a day of one particular product, and
there are such nine product manufactured in the factory.
There are two type of wastage in factory. First is the waste materials fallen on ground.
Such waste material is of 1% which is marginal and acceptable which goes into total
waste. Second types of waste are the biscuit collected in tray of the multi-pack wrapping
machine, since these biscuit are broken they are not packed and sold to the customer but
collected in other tray and sold as broken pieces and sold for less price for cattle feeding.
On the stalking table one to two rows of baked biscuits are kept aside for selling it as
loose biscuits. They are normally assumed to be damaged biscuits but they are not
damaged or broken but company keep such loose packets of biscuits to sell it to the local
people for marginal rate of 33 Rs / kg.
FOLLWING ARE THE MACHINERY USED IN MANUFACTURING
The Stephan TK Mixer is an ideal component to fully automatically feed the downstream make-up equipment for biscuits, bread, rolls, buns, cake, sweet goods, cookies and
The advantages are compelling:
High volume output results from the short kneading time and fast ingredient charging:
1000 kg/h to 6000 kg/h depending on the model.
Totally unassisted automatic discharge combines with predividing of the dough into
approximately 15 kg. Pieces, is the basis for a fully automatic operation without the need
for any full-time operator.
Dosing of flour, water, yeast, salt, shortening and other nutrients.
In a few seconds, all ingredients are homogeneously mixed. Then, as the dough begins
to develop, the Stephan energy meter control will ensure each dough is finished to the
The Stephan Mixer is most economical with:
No-time dough formula Straight dough Liquid broth (yeast slurry) system
Flour fermented liquid sponge system.
From batch to batch, the doughs will be consistently uniform: "Process Control"
Compact construction, no building preparation necessary, almost service-free day-today operation.
The direct drive design allows the kneading element to be fastened directly onto motor
shaft. There is no coupling or power transmission.
Easy to clean.
Only solid stainless steel construction.
Quiet operation, less vibration.
Count on a better result. In these competitive times, good kneading is not enough. For a
profitable operation, you need a short process time and an exact control on input energy
which allows you to mix each dough to the same development curve.
A short amortization of the capital investment occurs due to an increase in productivity more finished product from same amount of flour - and due to a perception of better
quality in the areas of longer shelf life, "a delicate crumb", softer crumb structure, higher
volume and increased flavor.
The process control is simple and reliable. The processes of ingredient loading, mixing
and dough discharge are controlled by each program. Depending on the ingredient
loading system design, the recipe change needs no change of program. However, if the
dosing system can not be adjusted independently, then a different program can be used
for each recipe. The ingredient loading system should be designed to allow each scaled
ingredient to be weighed during the mixing time of each previous batch. With this prescaling or staging of ingredients, all ingredients are ready to be charged at the same time.
This system design will save time and thereby increase output. This control system would
operate the entire loading, batching, mixing, discharging and dough conveying system.
This would include the logic for accurate scaling of ingredients.
Here's how the Stephan Mixer works.
The operation can be divided into four phases: loading, mixing, kneading and
discharging. After loading the mixer with all ingredients, the mixing process 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 Mixers are powerful and versatile.
Automatic make-up equipment is fed totally automatically by the Stephan Mixer. 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
The Stephan Mixer is also used efficiently in the cookie and cracker industry for
products such as:
With only two different mixing and kneading tools, all of the above described products
can be produced.
structure in corrosion-proof; anodised aluminum
and Aisi 304 stainless steel
satin stainless steel panelling
swivel wheels and
trays loader with automatic chain feed
feeder roller anodised aluminium
presser roller in White rubber
bronze moulder roller with quick change system
scraper blade in stainless steel
pressure adjustment of rubber roller on moulder
scraper blade adjustment
closed ring outlet belt with tension and centering
belt cleaner blade with extractable drawer
product outlet with power driven roller
1.00 kW speed variator
The biscuit coming from stripping conveyor is directed on to the cooling conveyor to
transfer the heat in the biscuit to atmospheric air as it is passing on it. The total travel of
the cooling conveyor is 1.5 times the oven length. As per need specifications it need the
travel of 150 ft. for effecting cooling. Cooling conveyor is made in a modular
construction of 2.5 Meters. long and connected together to form the required length. The
supporting side channels are fabricated from 3mm thick M.S. sheet.
Idle rollers are spaced at 750mm apart on conveying direction and 1700mm on the return
direction. All the idle rollers are of 48mm dia, mounted on 6004 ZZ deep groove ball
bearings with grinding finish and hard chrome plated for hygienic conditions.
During the production practically about the droppings of oil from the cloth due to rubbing
of cloth against tie angles when producing high fat biscuits. To minimise this is replaced
the all tie angles also with idle rollers. This might costs little extra, but you can maintain
hygienic conditions at working area.
Drive drums are two no's. of 220mm dia and projections are made on the surface of
drums to minimize slip or covered with friction grip rubber tape. Manual tensioning and
tracking are provided.
You can rely only on feeder table to stack the oil sprayed biscuits which does not require
more travel after oil spraying.
Laminators are generally used for production of all kinds of hard biscuits, crackers and
cocktail snacks. With laminator it is possible to create a puffy pastry-like structure, which
is of decisive importance for the quality level and consequently for the sales success.
Laminating of Dough band improves the weight/volume ratio considerably i.e., quantity
increase at same weight.
In this superior functioning machine the dough band received from sheeter of 838mm
width is passed through two shuttles. The dough sheet is cut into pieces by a knife for a
length of 1000mm (39") and these pieces are laid on bottom shuttle by top shuttle. This
bottom shuttle layers the pieces on first conveyor unit of 1000mm (39") wide production
line very carefully. The first conveyor unit feeds to the first gauge roll unit. No. of layers
can be controlled by the speed of first conveyor unit or increasing the speed of sheeting
unit and laminator by A.C. variable frequency drive.
BISCUIT BAKING OVEN
Construction: 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. And it is 260 feet long.
The complete chamber are insulated with minerwoll filled from outside to conserve heat
and increase efficiency. 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.
The baking in the heating chamber takes place by radiators located under and above the
wire mesh band which distribute heat for uniform baking. The recirculation heating gases
of these radiators can be controlled for each zone separately. The closed recirculation
system is having slight vacuum so that combustion gases can not enter into the baking
chamber. The ventilating fan is for circulation of the heating gases through the
recirculation system and thermostatically controlled burners provide the set temperature
of the heating gases.
All the circulating fans are fabricated from M.S. & S.S. and will be well balanced to
avoid vibration and will give noise free operation in high speeds
The single head rotary cutter prints fine design on a continuously fed dough sheet and
also cuts out the individual dough piece.
The unit powered by 1.5KW helical geared motor and speed controlled by AC frequency
controller. Drive is given to cutting roller only to accommodate different sizes of die's in
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.
The counting unit counts and see that the biscuit making process is going fine or not, i.e.
as per the program set in the machine, program is set as per the grams required. Generally
16 biscuits are taken by the counting unit so that it leads to 100 grams.
Turbulence System and Steam Extraction:
APPLICATION: The machine is used to granule (crystal) sugar to make it in powder
form for using in biscuit recipe.
DESIGN: Hammer Mill type, body of the machine is fitted on a sheet metal
box/container/receiver with one air exhaust balloon. The driving motor is fitted on the top
of the box. In case of auto feeding a bucket elevator is fitted at one end of the box.
OUTPUT: 10 Kg/min. (icing sugar)
POWER LOAD: 5 HP for grinder, 1 HP for auto feeder with built-in control panel
MULTIPACK WRAPPING MACHINE
This machine helps in wrapping the biscuits on the particular wrapper fixed on the roller
of the machine. The wrapper is feed into the machine and the sealing of the wrapper is
done by four heater roller, which is fitted on the machine. This heater roller heat up the
plastic and seals the packet. And at the same time the jaw cutter cut the packet on the
cutting edge marked i.e. as per the grams of the packet which is feed in the automatic
machine (100 – 120, 120 – 150, 150 -170, 170 - 190). The packets coming out from the
wrapping machine in a minute is programmed in computer and can be changed as per the
Poly bags contain 24 packets of parle g biscuits in one poly bag. There are 4 workers
employed on this section who take care of the work by putting 24 packets of biscuits in
the bag and forwarding it to sealing machine section.
The sealing machine has heater rod for sealing the poly bag in which 24 packet of biscuit
are placed, and it have a conveyer belt on other side so that when the poly bag passes
through the heater and get sealed then it is passed to the tapping machine.
Six such poly bags are placed in one such corrugated box and the box is passed through
the tapping machine where are tapped and then 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 world wide.
MACHINERY USED IN MAINTENANCE OF MAJOR MACHINERY
Pantograph and many more.
USE OF COST CUTTING MEASURES.
All the biscuits are manufactured in this factory i.e. In Mumbai one as the load of work
exceeded many factories were set up in other states of India. So the cost of transportation
decreases and more profit is earned.
Another example is of “Hide and Seek” one of the products of the company, for which
they used to import chocolate chips from Australia but later when it was available in
Chennai so the import was stopped and the cost dropped by a rupee because the duty
which was on the import was high and then another supplier was found in Hyderabad and
the price was again reduced by a rupee which finally ended up at 14 rupees.