Bikanerwala

Department of Biotechnology
Sainath University
Jharkhand, India
Training Report / Project Report on
15--2015 to 15--2015
BIKANERVALA FOOD PVT. LTD.
For the partial fulfilment of Degree in Biotechnology as part of
curriculum under Project Oriented Professional Training in 8th
Semester.
SESSION 2012-15
Submitted By: Under the guidance of
Manjeet Sharma Sh. Vedpal Yadav
Enroll- M.Sc (Food Science & Technology)
E-Mail- manjeetsharma.hisar@gmail.com Government Polytechnic, Mandi Adampur
Contact No. +919560298613 E mail– vedpalp@yahoo.com
Contact no. +9194165-89819

ACKNOWLEDGEMENT
To achieve any organizational goal needs a team work and achieving a personal goal is also
requires guidance, hard work, learning and execution which can not do without a team. I
would like to thanks all the support and guidance provided by the “BIKANERVALA Pvt.
Ltd.” Rather I would take the privilege to call it as “BIKANERVALA Family”., without
whom this project was not possible.
I would like to thanks Ms. Swati Chawla (HR Manager) for their administrative
support and guidance which is entry point to this project. I sincerely mention the technical
team headed by Mr. Rajesh Kumar Gupta (Manager QA) and Mr. Parvesh (Executive QA)
for giving me the atmosphere to learn like a professional and encouraging me towards the
accomplishment of my project. Special Thanks to Mr.Rajesh Kumar Gupta for sharing his
valued and lasting experience.
I am thankful to Mr. Vedpal Yadav Lect. Of Biotechnology in Sainath University for
guiding me to do this intership. I can not forget to thank to the all Lect. of Sainath University
for giving me all the support and guidance to pursuing such great course of Biotechnology.
CONTENTS

1. Introduction
(a) Cookies Section
(b) Bakery Section
(c) Chat Section
(d) Sweets Section
(e) Namkeen Section
2. Packaging Unit and Storage
3. Quality Assurance
4. cleaning and Sanitation
5. Hygiene and sanitation
6. Hygiene and Sanitation
7. Conclusion
INTRODUCTION

History:- Bikanervala is one of India's most prominent families in the business of traditional
hospitality products like Sweets and Namkeens. Our forefathers devoted their lifetime in
developing exclusive recipes which are now our proud family secrets. To this wealth of
inherited knowledge our new generation has now added another dimension - Modern
Technology.
Today, BIKANERVALA FOODS PVT. LTD. is an ISO 9001:2000, HACCP
and SQF 2000cm
certified company with four modern manufacturing units in the National
Capital Region and a chain of 88 outlets in India and abroad, serving vegetarian North Indian,
South Indian, Continental, Chinese cuisine and Fast food along with a vast variety of
traditional Indian sweets and snacks.
2. Departments- The Company has various Departments as per hierarchal company law.
The following are the main department working in this company.
(a) HR Department – it is the head office of the plant and this department controls all
the activities regarding human recourse development. The main function this department is
to maintain records for all the activities of the plant the complete administration of the plant
is carried out under this department It has it various subsections like accounts, administration,
security and training. This department keeps all the records and finances of the unit.
(b) Marketing Department –This department deals with all the activities of purchase/
sale of raw/furnished materials to the market. It has two sub-section to distribute the activities
for effective management i.e. Purchase section and Sale Section. This department is solely
responsible to provide raw materials, machines, packaging material etc. Records of all the
company assets are maintained by this department only. It has the additional responsibility of
surveying the market to improve the sale and quality of product.
(c) Production Department- The production of the company solely lies on this
department. The company has various products with the help of the hard work put by this
department. The following are many products by this company. It is divided.
In Six Main Sections:-
(i) Namkeens (ii) Sweets
(iii) Biscuits and Cookies (iv) Bakery
(v) Petha (vi) Chaat
(d) Quality Control & Assurance department- The company is operating with
qualified technician with high standard of quality control the department deals in the
sustaining of quality of all of its products and their variants. Besides this it also deals in the

Quality Certification (ISO 9001 2008, SQF, HACCP etc.) and their implementation and
continuous improvement in the company. They also help in maintaining CCPMM (Consumer
Complaints per Million Pack) etc.
(e) Maintenance Departments- This department is soley responsible for maintenance of
all assets of the company. It provide assistance to all the department for their proper
functioning. Proper functioning of all the machines in various department lies with this
department. They are capable of doing even third line servicing to all the machine. The
repair, requirement of the machines is done through this department.
(f) Store and Logistic Department- This department is related to the finished goods as
well as raw materials also. It maintains FIFO and appropriate condition for the storage of
materials, where logistics dispatch the finished goods to the distributor or according to the
procedure they also maintain FIFO for the dispatch.
3. Present Operations- BIKANERVALA’s Activities include manufacturing and marketing of
Bikano range of sweets, snacks, sharbats and papds with strong national distribution and
export net work. Apart from that there also.
(a) BIKANERVALA family restaurant- A chain of 100% pure vegetarian multi cuisine
sweet shops cum restaurant in India, UAE, and Nepal.
(b) Bikano Chaat Cafes- A chain of fast food outlets catering to the needs of youth and
not so young in a hurry, serving traditional Indian chaat in a global manner.
4. Achievements- Its R&D Division has developed a range of high nutrition supplements
known as weaning FOODS for childrejn which are distributed through the state governments
in rural areas. Apart from this BIKANERVALA is expanding its outlets in India as well as
Abroad. Focusing on promoting Indian heritage, culture and cuisine world wide.
5. New Launching- The company is preparing to launch first it is out let in Jammu and
Kashmir. Touching again in global branding in food industry the company is going to open it
out let in UK very soon.
ISO- CERTIFICATION
6. ISO 9001:2008 Quality Management System:- ISO 9000 is known as its standards for
Quality Management System. ISO 9000 is maintained by ISO (International Organization for

Standardization) and is administered by accreditation and certification holders. The
requirements of ISO 9000 : 2008 includes:
(a) A set of procedures that cover all key processes in the business.
(b) Monitoring processes to ensure that they are effective in keeping adequate records.
(c) Checking of defects, with appropriate and corrective action where necessary.
(d) Regularly reviewing individual processes and the quality system itself for
effectiveness.
(e) Facilitating continual improvement.
(f) The various sections of ISO 9001 : 2008Quality Management system are as follows-
Section 1: Scope
Section 2: Normative Reference
Section 3: Terms and definitions
Section 4: Quality Management System
Section 5: Management Responsibility
Section 6: Resource Management
Section 7: Product Realization
Section 8: Measurement, Analysis and improvement
(g) In effect, users need to address all section 1 to 8, but only 4 to 8 need implementing
with in a QMS. In additions of these ISO 9001:2008 requires a quality policy and
quality manual, which may or may not includes the following documents.
Control of Documents (4.2.3)
Control of Records (8.2.4)
Internal Audit (8.2.2)
Control of Nonconforming Product / Service (8.3)
Corrective Action (8.5.2)
Preventive Action (8.5.3)
(h) Advantages- It is widely acknowledged that proper quality management improves the
business and having a positive effect on investment, market share, sales growth, sales
margins, competitive advantage and avoidance of litigation implementing ISO often gives the
following advantages:
(i) Creative effective operation
(ii) Increase customer satisfaction and retention
(iii) Reduce audits objections

(iv) Enhance marketing
(v) Improve motivation, awareness and morale of employee
(vi) Promote international trade
(vii) Reduce waste and increase productivity
(viii) Increase net profit
(ix) They are also in the process of implantation ISO 22000-2005 (FSMS)
7. HACCP (Hazard Analysis Critical Control Point)- HACCP means the quality product so
this quality policy make safe product for the consumer. The concept of HACCP is to provide
systematic approach to controlling safety hazards in a food process. Hazard analysis of
specific food from harvest to consumption and identification critical control points and
application the criteria necessary to prevent eliminate of reduce to acceptable levels the
hazards in the entire food production sequence for specific food.
8. GMP (Good Manufacturing Practices)- GMP is a term that is renowned for the control
and management of manufacturing and quality control testing foods and pharmaceutical
products. Since sampling product will statistically only ensure that the samples themselves
are suitable for use and end point testing relies on sampling. GMP takes the holistic approach
of regulating the manufacturing testing environment it self. An extremely important of GMP
is documentation every aspect of the process activities and operations involved with product
manufacture. It the documentation showing how the product was make and tested is not
correct and in order, then the product does not meet the required specification and is
considered adulterated GMP requires that all manufacturing and testing equipment has been
qualified as suitable for use and that all operational methodologies and procedures utilized in
the food manufacturing process have been validated to demonstrate the they perform their
supposed function (s).
OUR CONCEPT

BIKANERVALA The traditional Indian sweet shop cum restaurant is an experience in
itself. Here you can find the pleasure & warmth of traditional Indian Sweets, Namkeens,
Chaat & Snacks and 100% pure Vegetarian multi cuisine restaurant which is served &
delivered with passion and celebration. Bikanervala’s concept always has been to innovate
and yet maintain the original flavour of traditional Indian food with primary focus on quality,
hygiene and affordability. Customer satisfaction is like a religion at Bikanervala and that is
why we have been able to keep our century old tradition alive. Bikanervala showrooms are
located in India, Nepal, UAE & New Zealand. BIKANO Bikano is our international brand
of packaged Sweets, Namkeens, Papad and Sherbets, manufactured to the world standards of
hygiene and quality. Bikano’s packaged products have always been a big hit with customers
in both India and abroad. Their food products like namkeens, cookies and syrups have made
it the most preferred in between meal snack all over the world. Bikano’s concept of constant
innovation through the use of modern technology for packaging retains its original flavour for
maximum time period. With this vast variety of finest packaged products one can always
ready to celebrate a sweet moment, any time , any where. Bikano products are available in
Bikanervala & Bikano Chat Cafe showrooms and in leading super markets and retail stores in
India & abroad.
PRODUCTION

Bikano prides itself in successfully integrating ultra modern technology to manufacture its
traditional food products in their 5 factories across India. Their products are quite well known
for being healthier than the oily snacks that are found outside since they are fried in machines
which are programmed by Programmable Logic Controllers (PLC). They have always been
in the forefront in pioneering new technology for modifying traditional sweet recipes of Kaju
Burfi, Khoya Burfi, Patisa, Soan Papdi etc. to having a longer shelf life and exporting them
abroad. They are specially packed under ambient conditions through an application called
MAP (Modified Atmosphere Packaging).The canned food products are very popular amongst
Indians abroad, and utmost care is taken to ensure that each of the products undergoes
stringent quality test.
Quality Control
Every product that comes out of Bikano’s factory is passesthrough stringent quality checks
before it reaches the customers. Their state of the art manufacturing process has been
awarded ISO 9001: 2000 by UL India Ltd and they are also an HACCP and SQF 2000 CM
certified organisation by SGS India Ltd. The Quality Assurance Department has world class
testing facilities for Colorimetric, Chromatographic, Chemical, Bacteriological and Physical
analyses thereby ensuring quality of raw material, packaging material, packing material and
finished goods. The quality standards are at par with the requirements of FDA, and Australian
and New Zealand regulations. The demands for their products are a testament to the quality
standard held by Bikanervala.
Cookies Section

Introduction: - The Cookie section of the plant is adjacent to the chaat café. The
products of the section are as follows.
Sr. Product Name
1. Kaju Pista Cookies
2. Milk Pista Cookies
3. Spl Namkeen Cookies
4. Fruit cake Rusic
5. Atta Patti
6. Marble Cookies
7. Elaichi Khjur
8. Chocolate Kaju
9. Jam Pista
10. Milk Kaju
11. Coconut Biscuit
12. Gol Kaju
13. Namkeen Kaju
14. Khajur
15. Fool Biscuit
16. Chanekt Cookies
Baking Temperature of Different Products :-

Listed below the different temp and time for the different products:
Sr. No Product Name Temp (C) Time (Minutes)
1. Kaju Pista Cookies 195 20
2. Milk Pista Cookies 168 18
3. Spl Namkeen Cookies 175 20
4. Fruit Cake Rusic 170 70
5. Atta Patti 190 16
6. Marble Cookies 190 16
7. Elaichi Khjur 190 16
8. Chocolate Kaju 190 16
9. Jam Pista 190 16
10. Milk Kaju 168 18
11. Coconut Biscuit 55 20
12. Gol Kaju 195 20
13. Namkeen Kaju 190 20
14. Khajur 190 20
15. Fool Biscuit 175 25
16. Chanekt Cookies 170 20

Process Flow Chart:-
Process Flow Chart of Different product shown below:
CHHOTA NAMKEEN
RECEIVING INGREDIENTS
Ghee, RW Flour, Salt, Ajawain, Glucose
SHORTING OF MATERIALS
DOUGH MAKING
WEIGHING 200 GMS
ROLLING IN CYLINDRICAL FORM
HARDENING FOR EASY CUTTING
0˚C / 1HRS
CUTTING
PUTTING IN TRAY
BAKING
(165 0˚C / 25) MINUTES
COOLING
10-15 MINUITES IN ROOM TEMP
EVALUATING
A.C. INSPECTION
PACKAGING
SPECIAL NAMKEEN:-
(Ghee, RW Flour, Sugar Salt, B/ Salt Ajawain, Custard Powder)

DOUGH MAKING
(Mechanically)
SHEETING
SPREADING OF CUMIN SEEDS
CUTTING
PUTTING IN TRAY PARALLEL
BAKING
(175 0˚C / 20) MINUTES
COOLING
EVALUATING
Q.C. INSPECTION
PACKAGING
KAJU PISTA
Ghee, RW Flour, Sugar, Salt, B-Salt Ajawain, Custard Powder
DOUGH MAKING
Creaming Material Mixing and flour mixing
HAND ROLLING
RECTANGULAR ROLLING USING BARS

FREEZING
0˚C / 4 HRS
CUTTING SQUARE
SHAPING & PUTTING IN TRAY PARALLEL
BAKING
(195 0˚C / 20) MINUTES
COOLING
EVALUATING
Q.C. INSPECTION
PACKAGING
RECEIVING RAW MATERIALS
DOUGH MAKING
Creaming Material Mixing and flour mixing
HAND ROLLING
RECTANGULAR ROLLING USING BARS
FREEZING
0˚C / 4 HRS
CUTTING SQUARE
SHAPING & PUTTING IN TRAY PARALLEL
BAKING
(195 0˚C / 20) MINUTES
COOLING

EVALUATING
Q.C. INSPECTION
PACKAGING
MARBLE COOKIES
Mixing of Ingredients Mixing of Cocoa Power
(RW Flour, Oil, Glucose) and Carmel
MIXING OF BOTH PREPATIONS
LAYERING
3 layer cocoa mix between 4 layer of maida mix
ROLLING & SHEETING
FREEZING
0˚C / 4 HRS
HARDENING FOR EASY CUTTING
(0˚C /4 hrs)
CUTTING(SQUARE)
PUTTING IN TRAY PARALLEL
BAKING
(190 0˚C / 16 MINUTES)
COOLING
EVALUATING

Q.C. INSPECTION
PACKAGING
FRUIT CAKE RUSK:- It requires two stage of baking. The first step of baking is done
at relatively higher temperature which is followed by cooling
and then baking at comparatively lower temperature.
(Ghee, RW Flour, Sugar, Tutti, Salt, Baking Soda, Glucose)
FILLING IN TRAY
(3 kg/Tray)
INITIAL BAKING
170 ˚C / 70 Minutes
COOLING
0˚C / 4 HRS
CUTTING & PUTTING IN TRAY
FINAL BAKING
(155 0˚C / 30 MINUTES)
COOLING
(0˚C / 4 hours)
EVALUATING
Q.C. INSPECTION
PACKAGING
Bakery Section
1. Introduction the Products made in the bakery section are mostly exported or used in
the outlets itself. Thereby marinating quality and in hygienic condition. The

commendable part of this section is that the wastage is negligible. This leads to
maximum production and minimum wastage. The major products of the bakery
section are:-
Sr. No Product Name
1. Patties
2. Kulcha
3. Mini Burger
4. Pav/Band
5. Jumbo Bread
6. Milk Bread
7. Normal Bread
8. Pizza Base
9. Pep Chakri
10. Hot Dog
11. Puffs etc.
Flow charts for some products of bakery section as follow:
Puffs.
Oil Dalda Ghee, RW Flour, Salt, Water

DOUGH MAKING
HARDENING FOR 1 HOU
SHEETING USING MACHINE
COATING WITH HYDROGENATED FAT
HARDENING
(2-3 hrs)
LAYERING AND CUTTING
COATING WITH MILK
SPERIKLING CUMIN SEEDS
BAKING
155 0˚C / 1HOURS
EVALUATING
Q.C. INSPECTION
PACKAGING
PEP CHAKRI
Oil Dalda Ghee, RW Flour, Salt, Water
DOUGH MAKING

ADDING 550 GMS SUAGAR
MOLDING
HARDENING
(2-3 hrs)
BAKING
155 0˚C / 1HOURS
EVALUATING
Q.C. INSPECTION
PACKAGING
KULCHA
Oil, yeast, Gluten, RW Flour, Salt, Water
DOUGH MAKING
MAKING BALLS FOR 70 GMS EACH

PROVING IN PROFFING CHAMBER
COATING WITH HYDROGENATED FAT
22 Minutes/43.5˚C /RH-24%
SHEETING
BAKING
200˚C/10 MINUTES
EVALUATING
Q.C. INSPECTION
PACKAGING
Flow Chart for Some Products of Chaat Section as Follow:-
1. Introduction: - Street food in India is liked by all. Thus Chaat section at
BIKANERVALA is producing all the month watering. Delicious street food. All the
food products manufactured here are directly sent to the outlets where they are further
processed and the sold. The major products of this section are as follows:-
Sr. No Products
1. Gol Gappa
2. ]Raj Kachori
3. Samosa
4. Bhakad Wadi
5. Peanut ckikki
6. Till Chikki
7. Kachodi

SAMOSA
Process flow Chart of Samosa
Oil, yeast, Gluten, RW Flour, Salt, Water
DOUGH MAKING
Mechanically
MAKING DOUGH BALLS
FLATTING USING WOODEN ROLLER
MAKING CONE OF EACH HALVES

FILLING MASALA INTO CONICAL HALVES
CLOSING BASE OF CONE MANUALLY
PATIAL FRYING IN REFIEND OIL
COLLING FOR 2-3 HOURS
TEMPORARILY PACKED AND SENT TO OUT LETS IN
HALF FRIED CONDITION
PAPAD SECTION
1. Introduction:- Different Types of Papads are made at BIKANERVALA which
includes Disco, Kali Mirch, Punjabi etc. The Whole papad making process is mechanized
everything from molding, sheeting, heating and colling is carried out in the same
machine. One papad take around 10 mins for complete processing. Moisture content in
paped is 11-12%.
Pudina Matti (Ingredients)
1. Wheat Flour
2. Edible Vegetable Oil
3. Salt
4. Coriander
5. Water Ghee
6. Mint Leaves DRY MIXING OF ALL INGREDIENTS
MIX PROPER WITH WATER

TIGHT DOUGH FORM
CUTTING IN MEGA
MAKING SMALL BALL
HOT BALLS WITH WODDEN ROLLER
FYING IN OIL
COLLING
PACKAGING
Packaging Materials used in the company
1) Polypropylene
2) Polyester
3) Polystyrene
4) Paper board
5) Glass
6) Tin cans
1) Polypropylene: It is a homogenous, unprinted film of pure polypropylene or a
copolymer of polypropylene and others such as ethylene. The properties include:
a. Low density
b. Low water vapour transpiration rate
c. Good Stiffness
d. Resistance to cracking
e. High tensile strength
f. Heat seal ability
g. Polypropylene may be used for shrink wrapping or heating in bags.
2) Polyester: polyester belongs to the class of condensation polymers which is formed
by eliminating a small molecule usually, water from two different reactants leaving
binding sites which enable two reactants to join together into long chains. The most
important polyester in packaging is polyethylene terphthalate (PET). It is an important
packaging resin primarily because it combines at very high temperature, excellent
mechanical properties with inertness to the film. The oriented films and sheaths are
very clear, have excellent strength and toughness and posses oxygen and carbon
dioxide barrier properties than any of other films

3) Paperboard and fiberboard - Paperboard is thicker, flexible and used for wrap
and bags. Fiberboard is made by combining layers of strong papers and is used for
constructing secondary shipping cartons. The material used to construct shipping
cartons is referred as corrugated paper board because of wavy inner layer of paper
board. Kraft paper is the strongest of the papers and in its unbleached form is
commonly used. Acid treatment of paper pulp modifies the cellulose and gives rise to
water and oil resistant parchments of considerable wet strength. These papers grease
proof or glassine papers and are characterized by long wood pulp fibers which impart
increased physical strength.
4) Polystyrene- Polystyrene is a non flexible polymer film of styrene- acrylonitrile
copolymer is made flexible by biaxial orientation of its molecule. Orientation is
produced by stretching under elevated temperatures. Polystyrene is widely used in
form of disposable cups and plates as well as in films and containers for packaging.
Polystyrene is amorphous, clear hard, brittle, low strength material with a relatively
low melting point and poor impact resistance.
5) Glass- Glass is one of the oldest packaging materials used. Its still very popular
because of its certain advantages:
a) Chemically inert
b) Transparent
c) Offers excellent barrier property
d) Highly impermeable to oxygen to oxygen, moisture, and other gases
e) Low cost
f) Rigidity
But it also certain limitations
a) Bulky
b) Breakage during filling, transportation and storage.
6) Tin cans- Tin plate cans continue to be the major work horse for packaging of
processed foods. They have distinct advantages namely: reliability, safety, pilfer
proofness recyclability, strength to withstand transportation, lower energy
consumption, retortability under high temperature conditions, high speed filling,
closing etc.
Significant advances have taken place in field of organic coatings used in
coatings used for protection for protection and wide choice of resins including epoxy;
acrylic, polyester, vinyl etc. are now available.
Peelable Easy open ends for Metal Cans
Peelable Easy open ends for food cans are rapidly finding their way into
markets all over the world. There are various versions available which enable easy
opening, reducing costs, faster production, and acceptable integrity levels.

QUALITY ASSURANCE DEPARTMENT
Quality can be defined as the state of “Zero Defect” The Quality Assurance
Department has world class testing facilities for colorimetric, physical, chemical, and
bacteriological analysis. Thus quality of incoming raw material, packaging material, finished
goods is ensured. Their quality standards are at par with requirements of PFA and
Australian and New Zealand Regulations. The hallmark of their quality is increasing
exports to satisfied customers the all over the world.
Functions of Quality Assurance Department
1) Receiving and analysis-
This includes
a) Analysis of raw material
b) Analysis of in- process material
c) Analysis of finished product
2) Monitoring during Production
This includes keeping a check on recipes & manufacturing procedures followed by
workers in various production units as well as hygiene condition.
3) Storage and Dispatch
Quality Assurance Department ensures there is no damage to food when it is stored
before dispatch. It also ensures the food products are dispatched with a complete check on
quality and hygiene
4) Research and Development
Quality Assurance Department is actively in product improvement and new product
development

5) Monitoring at service outlets
It performs fortnightly audit to keep a constant check on the sanitation of various
outlets. It follows the FIFO (first in first out) method.
QUALITY TESTING
1) TESTING OF MILK
I) Fat test (Gerber Method)
• Take 10 ml H2SO4 in a standard milk butyrometer (0-10%).
• Add 10.75ml of milk; pour it slowly through walls of butyrometer.
• Add 1ml of amyl alcohol.
• Shake it carefully until milk is dissolved.
• Centrifuge butyrometer in centrifuge machine for 1-2 minutes.
• Take out butyrometer and read the scale.
II) Acidity Test
• Take 9 ml of milk in a clean flask.
• Add 3-4 drops of phenolphthalein indicator.
• Titrate it against 0.1 N NaOH.
• Pink colour indicates the end of titration.
Acidity as lactic acid (%) = 9 X V1 X N = V/10
10*0.9
V1-volume of N/9 NaOH
N – Normality of NaOH
III) SNF Content
• Corrected Lactometer Reading(CLR) = Lactometer reading (LR)+ (T-27) x
0.2
• SNF =CLR/4 +0.25x Fat+0.6

IV) Adulteration Test
a) Urea Test
• Take 2 ml of milk in test tube
• Add 2 ml of tetra dimethyl 1 amino benzaldehyde (urea reagent)
• Appearance of yellow colour shows presence of urea.
b) Starch test
• Take 5 ml of milk in a test tube.
• Add few drops of iodine solution
• Appearance of blue- black colour indicates presence of starch.
c) Neutralizer test
• Take 2 ml of milk in a test tube
• Add 2 ml of neutralizer.
• Mix it properly.
Appearance of pink colour indicates presence of neutralizer.
2) TESTING OF KHOA, DHAP AND PANEER
1. Fat Test
Fat percentage in khoya, dhap is an important parameter of testing
quality of Khoya because the final product depend on the quality of Khoya
used.
• Take 10 ml H2SO4 in a standard milk butyrometer (0-40%).
• Add 3g of sample (khoa, dhap or paneer)
• Pour boiled water slowly through walls of butyrometer.
• Add 1ml of amyl alcohol.
• Shake it carefully until sample is dissolved.
• Centrifuge butyrometer in centrifuge machine for 1-2 minutes.
• Take out butyrometer and read the scale.
II) Moisture Content
• Take a moisture dish & put a glass rod in it and weigh.(A)
• Take 3 g khoa or dhap
• Add small amount of distilled water &slurry
• Keep in oven at 120° C for 2 hrs
• Take out and keep in desiccator for cooling
• Weigh(B)
% Moisture = (A-B) x 100/wt. of sample
III) Butyro-refractometer reading
• Take 20 g of khoa or dhap in a beaker.

• Keep beaker in microwave for extraction of fat.
• Maintain the temperature of butryo-refractometer to 40° C using hot water.
• Place 1-2 drops of oil extracted on lower prism of butryo-refractometer
• Note the reading
2) TESTING OF OILS AND FAT
The quality of fresh oil and processed oil depend on some factors like
peroxide value, fresh fatty acid content, iodine value, Moisture Content etc. All tests
are performed in every receiving of fresh oil from supplier. Peroxide value
determination is done in every hour of frying in process.
I) Moisture Content
• Take moisture dish &weigh it
• Weigh around 5 g of sample(A)
• Keep in oven for 120° C for 2 hrs
• Take out sample and let it cool in desiccator
• Weigh again(B)
% Moisture = (A-B) x 100
Wt. of sample
II) Peroxide value
Principle: The degree of oxidation that has taken place in a fat or oil can be
expressed in terms of peroxide value. When the double bonds of unsaturated fats
become oxidized, peroxides are among the oxidation product formed. Under the
acidic conditions these peroxides can liberate iodine from potassium iodine added to
the system. The amount of iodine liberate is then a measure of peroxide content,
which correlates the degree of oxidation already experienced by the fat.
• Weigh 5 g of sample in a clean dry flask.
• Add 30 ml of chloroform & acetic acid mixture (2:3)
• Add 0.5 ml of saturated potassium iodide solution and shake it for 1-2 minutes.
• Add 30 ml of distilled water to it
• Add 4-5 drops of starch indicator
• Titrate it against .01N sodium thiosulphate
• Titrate till blue black colour disappears
• Note titer value.
PV= Titre value x 10
Wt. of sample
Inference :- Oil Sample having PV up to or below 3 is acceptable. Oil which gives PV
beyond 3 is immediately replace with fresh oil.
III) Free Fatty Acid (FFA)

Principle: Fats are degraded by the process of hydrolysis, which in the
presence of moisture splits its triglycerides into their basic components of glycerol
and free fatty acid. This type of deterioration refers to hydrolytic rancidity which is
favored by moisture, high temperature and lipolytic enzymes. Free fatty acid content
is determined on the basis number of milligrams of sodium hydroxide necessary to
neutralize 20g of fat or oil.
• Weigh 20 g of sample
• Add 50 ml of neutralized alcohol
• Then put flask on hot plate for boiling
• After boiling add 3-4 drops of phenolphthalein indicator
• Titrate with 0.1 N NaOH
• Titrate till pink colour appears
• Note titre value
FFA = Titre value x 28.2(oleic acid)
Wt of sample
Procedure for perpetration of neutralized ethanol:
Take required amount of ethanol in a flask and add 5-6 drops of
phenolphthalein indicator. Titrate it against 0.1 N NaOH till light pink color is
obtained and retained.
Inference: for processed oil maximum % FFA content permitted is 1%
For refined oil maximum % FFA content permitted is 0.1%
IV) Butryo-refractometer reading
• Maintain the temperature of butryo-refractometer to 40° C using hot water.
• Place 1-2 drops of oil extracted on lower prism of butryo-refractometer
• Note the reading
V) TBHQ Test
• Take 20 ml of sample
• Add 3.5 ml of dim ethylamine
• Add 10 ml of methanol
• Shake it 2-3 min
• Presence of brick layer indicates presence of antioxidant TBHQ in sample.
VI) Cloud Point
Principle: It is a test which measure the temperature for a melted fat to go to
the crystalline state by observing the point ay which cloudiness of the fat is complete
this test is generally done to determine the effect of storage condition on fats and oils.

• Take 50-60 ml of oil in beaker
• Put in a container containing ice cubes
• Then put a thermometer in a beaker
• Shake it with thermometer
• Note the point where thermometer is not seen from outside.
• Note the temperature
VII) Iodine Value
Principle: the degree of instauration of the fatty acid in fat and oil can be
quantitatively expressed by the iodine value of the fat. Iodine value refers the numbers
of grams of iodine absorbed by 100g of fat. Since the iodine value reacts at the site of
unsaturation, higher the iodine value the greater the degree of instauration in the fat.
Blank Titration
• Take an empty cleaned dried Stoppard flask.
• Add 25 ml of CCl4 and 25 ml of wijs solution
• Keep it in dark for ½ hr
• Then add 15 ml of 10% KI solution and 100 ml of distilled water.
• Titrate it against 0.1 N sodium thiosulphate till colour changes to pale red.
• Add 2-3 drops of starch indicator and titrate till white colour appears
• Note the Titre value.
2) Sample Titration
• Take an empty cleaned dried stoppered flask.
• Weigh 0.3- 0.5 g of sample
• Add 25 ml of CCl4 and 25 ml of wijs solution
• Keep it in dark for ½ hr
• Then add 15 ml of 10% KI solution and 100 ml of distilled water.
• Titrate it against 0.1 N sodium thiosulphate till colour changes to pale red.
• Add 2-3 drops of starch indicator and titrate till white colour appears
• Note the Titre value
Iodine value = Titre value (Blank- sample)x normality x 12.69
Wt of sample
Note: Blank Reading is obtained by above procedure without using oil.
Inference: Higher the IV for a samplem, greateris the unsaturation. Standerd the
value IV for cotton seed oil is the range of 97- 112.
VIII) Anisidine value / Oxidation Value

Principle: Oxidation value gives an idea about oxidation which has
occurred when oil is used at frying temperature. This oxidation value depends on the
absorbance of oil sample. Oxides which are formed during such exposure to oxygen
adversely affects stability of products. Higher the value of OV, more rancid is the oil.
• Weigh 0.2-0.3 g of sample in 25 ml volumetric flask
• Make up volume with petroleum ether
• Take 2 ml of anisidine solution in tubes
• For preparation of blank add 10 ml of petroleum ether.
• For sample take 10 ml of prepared sample
• Keep it for colour to be developed for 10 minutes
• Add petroleum ether in cuvettes and perform auto zero at 350 nm
• Analyze the sample. This would give the reading for Ab.
• After completion of reaction for 10 minutes.
• Put blank solution in both cuvettes and perform auto zero
• Analyze the samples and this would give reading for As.
O.V = {1.2 As- Ab} x 25
Wt of sample
Inference: OV standard for different products are different.
e.g. for bikaneri bhujia max value is 20
for aloo bhujia max value is 45-50
for crunchy munchy max value is 50.
4) TESTING OF WATER
Ι) Hardness of water
• Take 25 ml water sample in a conical flask
• Add 2-3 drops of Eriochrome black
• Add 2-3 drops of ammonia buffer solution
• Pink colour appear
• Add drop by drop ethylene diamine tetra acetate until violet colour appears
• Observe the number of drops added.
Multiply the number of drops with 5 or 25 depending on the ppm of solution used.
II) pH of water
• Take 50 ml of water in a beaker
• Calibrate the pH meter using buffer solution
• Measure the pH of water
•
III) Total Dissolved Solids
• Take 50 ml of water in a beaker
• Using a TDS meter record the observations in ppm

5) TESTING OF FLOUR
I) Gluten content
• Weigh accurately about 25g of material into dish.
• Add 15ml of water to flour; knead it by kneader or by hand.
• Keep the dough in a beaker cover it with water
• Let it stand for ½ hour
• Remove dough and knead it again in stream of water
• Spread wet gluten in thin layer
• Weigh wet gluten (A)and dry gluten kept in oven maintained at 100 C for 5
hours.(B)
Gluten = (A-B) x 100
Wt of sample
II) Sieve test
• Take 100g of flour.
• Sieve through 180 micron mesh
• Weigh amount retained in mesh
III) Alcoholic acidity
• Weigh about 5g of sample in 100ml conical flask provided with glass stopper.
• Add 50 ml of neutralized alcohol.
• Allow to digest for 24 hours.
• Pipette 25 ml of supernatant liquid in conical flask and 1ml of phenolphthalein
and titrate with standard alcoholic NaOH.
Alcoholic acidity =24.52 x Normality of NaOH x Titre value
Wt of sample
IV) Total ash contents
• Weigh 5-6 g of material accurately.
• Transfer material into porcelain dish and weigh.
• Ignite material with a suitable flame.
• Complete the ignition in a muffle furnace at 500° C+/-20 °C.
• Cool in a desiccator and weigh.
Total ash (on dry weight basis) percentage by weight =100x (W2-W1)
W
W2 = weight of porcelain dish with ash
W1 = weight of empty porcelain dish
W = weight of material taken
V) Acid insoluble ash

Reagents: - 5N HCl
• To ash contained in a porcelain dish as obtained from procedure of total ash,
add 25ml of 5N HCl.
• Cover it with a watch glass and heat on a hot plate for 5-10 minutes.
• Allow to cool and filter the contents through Whatmann paper No.42.
• Wash the filter paper with residue in dish.
• Keep in oven maintained at 100 C for ½ to 1 hour.
• Ignite in muffle furnace at 600C for 3 hours.
• Cool the dish in a desiccator and weigh.
Acid insoluble ash % by weight = 100(W2-W1)/W1-W
W2=Weight of porcelain dish with acid insoluble ash
W1= Weight of empty porcelain dish
W=Weight of porcelain dish with material taken for determination of total ash
6) TESTS FOR PACKAGING MATERIAL
I) Laminates
• Colour and odour of packaging material is checked
• GSM(grams per square metre) is checked by cutting the packaging material of size 10
x 10 cm2
and weigh it
• Dip the piece of laminate in chloroform to separate the different layers and measure
them using a micrometer.
• Also note any kind of wrinkles and foul printing.
• Sealing condition should be observed. It should not tear easily.
• Dimensions of various pouches should meet the standards.
• Thickness should be measured using a micrometer.
II) Cartons
• GSM(grams per square metre) is checked by cutting the packaging material of
size 10 x 10 cm2
and weigh it
• Note the dimensions of cartons
• Bursting strength: clamp the carton between the clamps of bursting machine.
• Moisture: The cartons should not be too wet or dry.

• Appearance: The carton should have a uniform appearance. They should not be
wrinkled at place. The plies should adhere firmly to each other and should not come at
places.
• Condition of pins should be noted. They should not be rusted.
III) Tin Cans
• Dimensions should conform to standards.
• Thickness should be noted using screw gauge.
• Weight of can and lids should be noted.
In canning section of bikanervala A2 ½ can size is used for packaging of channa
& gulabjamun products.
Can testing
• Counter Sink = 3.20
• Seam Length = 3.00
• Cover Hook = 1.95
• Body Hook = 2.10
• Seam thickness = 1.30
• Actual Over loop = 1.30
• % Overlap = 47-54%
• TE = Thickness of End is 0.22
• TB = Thickness of Body is 0.23
Actual Overlap = CH + BH + TE – Width ( Seam Length )
% Overlap = Actual Overlap
2TE + TB – Width
IV) Glass Bottles
• Check for any kind of breakage and cracks.
• Verticality- to check bottle has retained the shape of mould during annealing and
cooling, bottle should stand perfectly upright.
• Dimensional Checking- dimensional checking is intended to ensure that bottle will
perform satisfactorily during filling, packing etc. The outer and inner diameter of the
neck of bottle is measured
• Capacity: Capacity is checked by filling bottle with water upto brim and noting
the volume.
7) TESTING OF NAMKEENS
I) Moisture Content
• Take moisture dish &weigh it
• Weigh around 5 g of sample(A)
• Keep in oven for 120° C for 2 hrs
• Take out sample and let it cool in desiccator

• Weigh again(B)
% Moisture = (A-B) x 100
Wt. of sample
II) Salt Content
• Weigh 0.2- 0.3 g of crushed namkeen in a clean dry flask
• Add 30 ml of distilled water
• Shake it for 2-3 minutes
• Filter the solution
• Take 10 ml of filtrate
• Add 5-6 drops of 5 % chromate indicator
• Yellow colour develops
• Titrate it using 0.1 N AgNO3.
• Stop titration till brick red colour appears
• Note the titre value
Salt % = Titre value x 58.5 x dilution x normality of AgNO3.
Wt of the sample
III) Stability
• Weigh 30 g of sample in clean dry flask
• Tightly plug it with cotton
• Keep it in oven at 120° C
• Start checking for rancid aroma in namkeen after 3 hrs
• Check after every 1 hr
• Note the time it gives a rancid aroma
• Stability for 1 hr shows shelf life of 20 days
IV) Peroxide Value
• Take 30 g of namkeen in a beaker
• Pour chloroform in it
• Cover it with a foil
• Filter it and take 10 ml of filtrate
• Add 30 ml of chloroform & acetic acid mixture (2:3)
• Add 0.5 ml of saturated potassium iodide solution and shake it for 1-2 minutes.
• Add 30 ml of distilled water to it
• Add 4-5 drops of starch indicator
• Titrate it against .01N sodium thiosulphate
• Titrate till blue black colour disappears
• Note titer value.
• Take 10 ml of filtrate in another weighed conical flask
• Heat it on hot plate to evaporate chloroform. This would give wt of sample in 10
ml of filtrate.
PV= Titre value x 10

Wt. of sample
CANNING
1. Introduction. Canning is a method of preservation of food by complete removal of
air. The products canned in this industry includes Rasogulla , Gulab Jamun , Raj bhog ,
Sponge Rasogulla etc. unlike in the canning of frults & vegetables, no step of exhausting is
done as no head space is left in the can. Canning is done by double seamer. Canning of one
can takes 15-20 sec.
After being canned the pressure and leakage in cans are checked. The
cans are dipped in water and one end of the can is attached to a pressure gauge which helps in
measuring the pressure. The water exerts pressure from outside which further aids in the

process of determining the correct pressure of the can. The correct pressure of the can is
15kg/sq.cm, anything more or less than that is not acceptable.
FLOW CHART FOR CANNING
RECTANGULAR SHEET OF TIN COATED STEEL PLATE
TIGHT DOUGH FORMROLLING OF THE SHEET TO
GIVE A CYLINDRICAL SHAP WITH A SIDE SEAM
FIRST OPERATION OF DOUBLE SEAMER
(SEALING CAN END BODY TOGETHER )
STERILISATION OF THE CANS (90-100C)
FILLING OF PRODUCT WITH SUGAR SYRUP
SECOND OPERATION OF DOUBLE SEATHER
COMPLETE LIDDING
DIPPING IN COLD WATER FOR THERMAL SHOCK
PUTTING PLASTIC LIDS
STORAGE
STORAGE
Storage section of the plant is good illuminated and situated at the ground
floor of the plant. Storage section is used to store the following materials.
1. Raw material such as cereals, flour, spices, sugar, salt etc.
2. Packaging material such as pouch laminates etc.
3. Chemicals
4. Stationary etc.
Storage process:- Before storage the materials is first inspected and tested for quality
parameter by the QA department of the plant. If the QA department passes the material it is
received by the store department. All incoming and outgoing records are maintained by the
computer using special software called “Enterprise resource Solution”.
Storage Condition:- Storage condition for all the raw material except dry fruits are
ambient and the dry fruits are stored in the temperature below 20o
C.

Personal hygiene:- Personal hygiene check list of the storage section covers all the
aspects personal hygiene like clothing,cape etc.which is continuously mained by the
department. Rat trap and bail station are continuously checked for rodent entry and there
result is also documented.
Shelf life:- Each stored which has limited shelf life is contentiously inspected and when the
shelf life found expiary the product is immediately transferred from the storage section.
Inventry Management:- Department head of storage always check their storage and
demand of the raw material to maintain the minimum stock of the raw material. According to
the production order it is very necessary to stock the material for at least one month.
G.M.P.(Good Manufacturing practices):- GMP guidelines for the storage like First-
In-First-Out is always performed by the storage section. Tag with product name is hanged at
place where the material is stored,so that there is a minimum chance of cross contamination.
The storage section is also equipped with automatic fire control.
CONCLUSION
The plant is well equipped with all the modern packaging machine, raw material
testing machine and finished goods quality testing. Company in also certified with HACCP,
SQF and ISO 9001-2000 certification. Spite of these things there is a big scope for the
standardization of process variable, cleaning and sanitation practices, insect and rodent
control etc. There are some findings and recommendation for above parameters to produce
the quality food and maintained of HACCP guidelines.
1. There should be well defined CCP (critical control point),there limit and there control
which should shown at that point Ex. wall of the plant.
(i) Metal detector and metal separator.
(ii) Chilling is leaks
(iv) There should the provision for insects control like insects killers in each
section of the plant.

2. Birds are sheltering at the entrance of the plant which is very necessary to control.
3. There is no air carton at the entrance of the plant.
4. There a big hole at the wall of packaging which open to the outside of plant. Hence there is
chance of insect and rodent contamination.
5. All walls of production & packaging section are very dusty which can produce a serious
contamination to the product. So the wall should be cleaned routinely by vacuum cleaner.
6. The insect & rodent controlled operator report that he is not satisfied with the other employ
co-operation to perform his work. Workers disturbed his bait station & trap.
7. The worker should use the florescence light to find the rat entry in the plant.
8. There should be a hand sanitizer at the entrance of the plant. So that any person who enters
to the plant can easily sanitize his or her hand with the chemical.
9. There should be a routinely medical check up of the health of the workers.
10. Before going to the processing extruder raw material should pass to the metallic
separator. So that any metallic contaminates which are going to the extruder barrel can not
damage the screw of extruder.
11. Hand wash/ sensitization including for all equipment & food contact surfaces are not
being done so as to achieve complete disinfection thereby.
CLEANING AND SANITATION
1. General Cleaning: - Effective cleaning and proper sanitation is the key to produce
a safe quality product. According to the nature of the food product manufactured in the plant
cleaning and sanitation practices are good suited and performed. Simultaneous floor cleaning
performed during production run. Cleaning solution normally contains the following
components.
(a) 2 Kg Causis Soda
(b) 3 Kg Acid Slurry
(c) 250 Liter water
When intense cleaning is required pure caustic solutions used.

2. Cleaning of Production Section:- The following steps are done while cleaning the
production section:-
(a) HCL is used for cleaning of toilet.
(b) Occasionally floor rinsing is done by authorized person who seeps the
floor with wiper & water.
(c) Cleaning of machinery is performed after each product changes and it is
done by air pressure and with cloths.
(d) Routinely cleaning of packaging machinery is done in 1 month when the
production gets off. It is done thoroughly by dismantling the machine.
(e) Boiling Kettle and other pans in sweet section are cleaned by hot water.
3. Cleaning Tools These following tools are as:
(a) Wiper
(b) Broom
(c) Clothes
4. Cleaning Material Placement:- All the Material related to cleaning and sanitation
are placed in a separate room behind the plant.
5. Collection and Disposal Garbage:- Garbage are collected in poly ethylene bags and
are disposed to dumping yard of the city. Liquid wastes are first treated in the ETP
(Effluent Treatment Plant) of the company and they sent to sewage line of the city.

Bikanerwala

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