Aloha scack bar project by students of MIT school of food technology pune

MAEER’s
MIT COLLEGE OF FOOD TECHNOLOGY,
LONI KALBHOR, PUNE
HANDS ON TRAINING REPORT
PRODUCTION OF “ALOHA SNACK BAR”
SUBMITTED BY
Group No. – IV
HARSHADA NARE MITU16BTFT0755
HRISHIKESH SUTAR MITU16BTFT0756
HUSSAIN MALA MITU16BTFT0757
SEMESTER- VIII (IV YEAR)
YEAR: 2020
GUIDED BY
Prof. K. A. Mane
MIT ART, DESIGN AND TECHNOLOGY UNIVERSITY, PUNE

CERTIFICATE
This is to certify that the project report entitled “PRODUCTION OF
ALOHA SNACK BAR”, submitted to the Faculty of Food Technology in
partial fulfillment of the requirements for the degree of B. Tech (Food
Technology) embodies the results of a piece of bonafide research work
carried out by Group No. IV under my guidance and supervision and that no
part of the report has been submitted to any other university for degree or
diploma or publication.
The assistance and help rendered during Hands on Training
Programme have been duly acknowledged.
Place: MITCFT, Pune Prof. K. A. Mane
Date: Associate Professor

MIT College ofFoodTechnology,
Loni-Kalbhor- 412201, Pune,
Maharashtra, India
CERTIFICATE
This is to certify that the report entitled “PRODUCTION OF
ALOHA SNACK BAR”, submitted to the Faculty of Food Technology in
partial fulfillment of requirements for the degree of B. Tech. (Food
Technology) embodies the results of a piece of bonafide research work
carried out by Group No. IV under the guidance and supervision of Prof. K.
A. Mane Department of Food Engineering, MIT CFT, Loni-Kalbhor, Pune
and that no part of the report has been submitted to any other university for
degree or diploma or publication.
Place: MITCFT, Pune Prof. (Dr.) V. N. Pawar
Date: Principal

ACKNOWLEDGEMENT
We sincerely owe an immerse debt of gratitude to the following people for
supporting and guiding our group ahead in the journey of making the project
report of hands on training which is a product of an effective team work.
Prof. Dr. V. N. Pawar, Principal of MIT College of Food Technology,
who motivated, planned and administered the entire process of hands on training
and helped us to successfully complete the project.
It is a genuine pleasure to express our deep sense of gratitude to our
mentor, philosopher and guide Prof. K. A. Mane, Department of Food
Engineering, who encouraged us to investigate various aspects and allowed us to
learn many things which made this whole experience a notably enriching endeavor
for us. She always took an initiative in correcting us timely so that we developed
best in ourselves.
Prof. D. N. Chaudhary, Head of the Department of Biochemistry,
without her guidance it would have been quite impossible for the group to carry
out effective analysis of the product.
Prof. F. L. Pathan, who motivated, planned and administered the entire
process of hands on training and helped us to troubleshoot many hurdles by
providing his valuable guidance and successfully complete the project.
We are grateful to all the staff members of MIT College of Food
Technology, for their kind co-operation during the conduct of sensory evaluation
of our product.

Last but not the least, we express our deep feelings of love and affection to
our beloved parents for providing us valuable opportunities which helped us to
stand out on our own feet on the stage.
We would like to take on record our sincere thanks to the Management of
MAEER’s MIT College of Food Technology, Pune for providing us a golden
opportunity to take graduation studies in this reputed institution.
Place: MITCFT, Pune Date:

INDEX
Sr.No. Topics Page No.
1) Introduction 01
2) General Information 04
3) Pre-requisite Launching 05
4) Plant Location 08
5) Plant Layout 10
6) Organizational structure 12
7) Procurement of Raw Material 15
8) Details of Processing Equipment’s & Machinery 24
9) Source of Fixed & Variable Capital 27
10) Product Manufactured 28
11) Product Manufacturing Process 33
12) Cleaning and Sanitizing Operations 39
13) Quality Control and Nutritional Analysis 42
14) Legal Aspects 55
15) Hazard Analysis and Critical Control Point (HACCP) 57
16) Implementation of ISO 9000 and food safety standards
22000 series
70
17) Packaging and Labeling 73

18) Storage Facilities 76
19) Cost Analysis, Production cost and Revenues. 77
20) Marketing and Sales 85
21) Production Details 90
22) Consumer Complaints 92
23) Effluent Water Treatment 93
24) Byproducts & Its Utilization 96
25) Problems and Difficulties Encountered During Hands on
Training
97
26) Conclusion 98
27) References 99
28) Abbreviations 102

1
CHAPTER 01
INTRODUCTION
Snack foods are very popular and very well known throughout the world and snack is a
portion of food, smaller than a regular meal, generally eaten between meals. Snacks come
in a variety of forms, including packaged snack foods and other processed foods as well
as items made from fresh ingredients at home. The Snack foods’ term is used for energy-
dense, nutrient poor foods. By contrast, the term ‘snacking’ refers to eating between
meals, irrespective of whether the food consumed was a ‘snack food’ or any other food
item. Nowadays, the consumption of fast-foods and snacks has increased at the same rate.
In this sense the development of cereal bar formulation as snacks present itself as an
emerging force in this niche market. Cereal bars are a popular and convenient food and,
therefore, would be an ideal food format to deliver protein and fiber.
Snack bars were introduced in the last decade as a wholesome alternative to comfit when
consumer shows more interest in health and diets. The association between cereal bars
and wholesomeness food stuffs is a well-documented tendency in industrial fields.
Snacking between meals, provides an important contribution to dietary intake of key
nutrients but may also contribute to excess energy consumption (Balasubramanian et al.,
2002). Snack bars are a relatively popular snack, but often are high in sugar, fat and
energy. Snack bars seek to meet the needs for indulgence, but also health and wellness
(Yan et al., 2015).
The greatest difficulty in obtaining a good snack bar is a combination of several
ingredients with specific functionalities such as minerals, proteins, grains, fibers,
thickening agents, sweetness and flavorings, and turns them into a product with flavor,
texture and decent appearance, while it tries to achieve goals specific nutrients. The
development of a product is essentially a problem of optimization. In the search of the
best formulation, the main objective is to determine the optimum levels of the

2
components or key ingredients, which are the independent variables or factors and the
dependent variable or response is the objective to be optimized.
A tool to choose the best formulation of the product is the sensory evaluation, which is
based on fundamental psychological perception and physiological techniques. Hedonic
scale is used by experts and untrained consumers from which best results are obtained.
The snack bars are formulated to include protein and fiber rich sources consisting of oats,
peanuts, amaranth, flax seeds, jaggery, watermelon seeds and ghee. 100 g of snack bar
gives 326 kcal and 12.3 g of protein with 16.7 g of fiber.
Amaranth is a good source of fiber, protein, manganese, magnesium, phosphorous and
iron. It serves as a good source of health promoting antioxidants and helps in lowering
cholesterol level. Flaxseeds provide good amount of protein, dietary fiber and omega-3
fatty acids in addition to being a rich source of some vitamins and minerals (Adda
Bjarnadotti et al., 2019) It is also a rich source of lignin which may reduce cancer risk.
Peanuts are rich in protein, vitamins, minerals and antioxidants (Atli Arnarson et al.,
2019). Most of the consumers are mostly attracted to snacks processed from healthy
ingredients such as cereals, oilseeds and ancient grains. Incorporation of protein and fiber
rich sources in diet will provide the fullness and fulfill the hunger as well deliver the
essential nutrients as per recommended daily intake.
In view of all these nutritional facts and consumer demand for nutritious snack bars it
was decided to develop nutritious snack bars.
OBJECTIVE
The purpose of this study is to develop a nutritionally enhanced snack bar with enhanced
levels of protein and fiber. The study also aims to evaluate the influence of breakfast
cereals and other components on sensory properties as well as nutritional improvement
on bars. It also delivers RTE food category with a focus on convenience and as ‘portable
nutrition’. The specific objectives of this study are;
 To promote healthy snacking with a higher nutrient content.

3
 To promote value addition of the snack bar.
 To promote healthy RTE snack foods, keeping in mind the changing lifestyle.

4
CHAPTER 02
GENERAL INFORMATION
 Name of the firm : Ternion- H
 Name of the guide: Prof. K. A. Mane
 Geographic location of the corporate office: MITCFT, Loni-Kalbhor, Pune
 Nature of business: Small Scale Plant
 Year of establishment :2020
 Range of products and their brand name: ALOHA snack bar
 Core product: Snack bar
 Type of the firm: Snack industry
 Market covered: Local retail market
 Annual turnover of the firm: ₹ 81,47,112

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CHAPTER 03
PRE-REQUISITE IN LAUNCHING A BUSINESS
ENTERPRISE
Product Analysis and Market Survey
The market analysis of the product was carried out in the local areas and urban areas
based on the demand of the nutritious snack, i.e. “on the go” type product in small
markets and retail outlets. There is a monopoly of products like snack bars in the market
with a range of less competitors. The global market is expected to have a huge demand
for bars in recent years. One of the key drivers of this market is due to consumer demand
of healthy, tasty and crispy snack bars to be consumed between the meals. The Indian
nutritional bars market stood at $ 9.4 million in 2018 and is projected to grow at a CAGR
of over 30%, to reach $ 46.2 million by 2024 [Research and Markets , 2012-2022].
Growth in the market can be attributed to increasing incidences of lifestyle diseases such
as diabetes, obesity, blood pressure, asthma, and other heart diseases and rising
consciousness among consumers towards healthy eating habits.
Fig.1 Pie chart of Indian Snack Bar Market
Major distribution channels include supermarkets, convenience and departmental stores.
The awareness of usage of bars as a snack is still in niche market in developing countries,

6
however, it is expected to grow faster in coming 6 years due to lifestyle changes in
middle class people in emerging markets such as India.
Some of the key vendors in the snack bar market are
 Snickers
 Mars
 Patanjali Energy bar
 Kellogg’s bar
 Supreme protein bar
 Nature valley
Areas explored –Loni-Kalbhor, Hadapsar, and Pune city
Name of the shops visited-
 Patanjali store, Loni-Kalbhor
 Big bazaar, Amanora mall, Hadapsar
 Star bazaar, Seasons mall, Hadapsar
 Kumar Pacific Market, Guru Nanak Nagar
Determining Size of Plant
Taking into consideration the criteria which specify that the space required should be 3
times greater than the area occupied by the equipment’s is followed while constructing
this plant. After considering various factors like in built up area(machinery size, storage
area, working space, etc. and parking area plant size was decided as 2,500 sq. ft.

7
Location
We rented the building in the Maharashtra Industrial Development Corporation (MIDC) area
of Wai, Satara.
Selection and Organization of Physical Facilities
The facilities like electricity, water are easily available from nearby sources. The
equipment’s were arranged according to the production of snack bars.
The other physical facilities like waste disposal, equipment cleaning, sanitizing and
environment sanitary facilities are required in food processing industries.
Building the Organizational Structure
Being a small-scale industry, the responsibilities and authorities regarding the
management of the plant were distributed among the group members. It is transparent to
all members, everyone knows whole work, so in absence of their members it can be
easily managed.

8
CHAPTER 04
PLANT LOCATION
5.1 Choosing the Location of Industry
Location is a very important factor to be considered while setting up an industry. A
location selected should be favorable for the production of concerned product. So various
parameters are emphasized to the select best suitable location and its description is
plotted below.
5.1.1 Selection of Location
Selected location –MIDC Wai
The following factors are considered for selection of location:
1. Availability of raw materials: Almost all the raw materials required for the production
of snack bars are available at the nearby location.
2. Supply of Labour: Labour force with low wages are easily available as location of the
plant is outside of Pune city and belongs to rural area.
3. Proximity to the market: It has proximity to the local market and has more demand at
the student level along with nearby population.
4. Availability of transport facilities: As MIDC well connected with the national
highway so transportation could be easily done.
5. Supply of power: Consistent power supply is available in MIDC area.
6. Climatic factors: Wai favours with good climate so as that climatic condition does not
affect the quality of snack bars. As the climate of the region is not too humid and too
dry so it favours proper storage of snack bars.

9
7. Existence of complementary and competitive industries: Being innovative and
nutritionally rich as compared to other snack bars produced by existing and
competitive industries this product has a large demand and has good competitive
factor to the other complementary industries.
8. Selection of the exact site: In MIDC, we found one entire building with good
construction and other facilities which matched with our production requirements so
it helped us save our cost of construction.
9. Disposal of waste: Disposal of waste-industry has a drainage outlet to carry the
waste out of its surrounding area. Solid waste is disposed away from the plant
at waste dumping areas so it does not harm the nearby environment,i.e.
according to Environmental Protection Act, 1967.

10
CHAPTER 05
PLANT LAYOUT
Plant layout is primarily concerned with the internal setup of an enterprise in a proper
manner. It is concerned with the orderly and proper arrangement and use of available
resources viz. men, money, machine, materials and methods of production inside the
plant.
Plant layout is a plan or act of planning, an optimum arrangement of facilities, including
human resources, operating equipment, storage space, material handling equipment and
all other supporting activities.
Types of Plant Layout
A) Product Layout
B) Process Layout
C) Cellular Layout
D) Fixed Position
Also, there are different flow patterns like I-flow, L-flow, U-flow, O-flow, and S-
flow.
Flow pattern: U-flow
A good plant layout is necessary in order to have greater space utilization, minimize
production delays, reduce congestion, increase output or shorten manufacturing time.
Factors considered in Plant layout:
Material Factor – Design, variety, quantity of raw material
Main Factor – Workers, supervision, service arrangement and safety

11
Machinery Factor – Process and processing equipment’s
Movement Factor – Transport and handling
Waiting Factor – Temporary storages
Service Factor – Employee facilities, washrooms, parking, etc
Building Factor – Utility distribution
Change Factor – Flexibility and expansion
Fig 5.1Plant layout of snack bar making plant

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CHAPTER 06
ORGANIZATIONAL STRUCTURE
An organizational structure defines how to manage the various departments by
coordination and supervision are directed towards the achievement of organizational
aims. Organizations need to be efficient, flexible, innovative and caring in order to
achieve a sustainable competitive advantage.Organizational structure can also be
considered as the viewing prospective through which individuals see their organization
and its environment.An organization can be structured in many different ways, depending
on its objectives.
The structure of an organization determines the modes in which it operates and performs.
Being a small-scale industry, it has a basic organizational structure with minimal
members. The authorities and responsibilities of various personnel are clubbed together
within the group members. The distribution of positions include:
 Plant Manager
Supervising the production and the complimentary requisites of the industry is the
responsibility of the plant manager. He/she to supervises the overall functioning of the
industry.
 Procurement Manager
He/she is responsible for ensuring a constant supply of raw material in the plant. He/she
is also responsible for quality checks of the procured raw material. He/she is required to
purchase the raw material from the local market. It is his/her responsibility to ensure
proper storage of raw material and take the necessary actions to check the spoilage.
He/she is also responsible for quality checks of the procured packaging material. He/she
is also responsible for designing of packaging material.

13
 Production Manager
He/she is required to monitor the quality of raw material being used, the actual
production, packaging and storage of product in suitable condition. He/she needs to
supervise the cleaning of equipment/utensils and maintenance of hygienic conditions in
the processing area.
 Analysis and Quality Control Manager
A lab in charge is responsible for estimating the product for its nutritional parameters.
The nutritional analysis of the product to estimate fat, protein, carbohydrate, moisture
content and estimating the shelf life of the product is the domain of his duties. He/she is
responsible to maintain quality of the product.
 Marketing and Sales Manager
He/she is further responsible for preparing marketing strategies and sales strategies of the
product.
 Finance Manager
Finance manager manages the finances of the industry. He/she looks into the clearance of
bills and taxes and he is responsible for taking care of, all the bank work related to the
industry.

14
Table 6.1 Organizational structure of the employees with their responsibility
Sr. No.
Authority Responsibility
1
Plant Manager
Harshada Nare
2
Procurement Manager
Hussain Mala
3
Production Manager
Hussain Mala
4
Analysis and Quality Control Manager
Hrishikesh Sutar
5
Marketing and Sales Manager
Harshada Nare
6
Finance Manager
Hrishikesh sutar
Table 6.2 Manpower
Sr.
No.
Designation
Monthly
salary per
person
No. of
people
requires
Total
expenses
1 Workers 12,000 4 48,000
2 Technician 18,000 01 18,000
3 Store keeper 15,000 01 15,000
4 Accountant 15,000 01 15,000
5 Plant supervisor 25,000 01 25,000
Total 1,21,000

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CHAPTER 07
PROCUREMENT OF RAW MATERIAL
India is an agricultural country, everything is easily available at cheaper price. The
quality of raw material directly affects the quality of product and the price of raw
material affects the price of product and profit directly. Hence, proper selection and
purchase of raw material is an important decision. We procured raw material, i.e. popped
amaranth seeds, oats, peanuts, watermelon seeds, flax seeds, jaggery and chocolates from
the local market of Wai.
7.1 Raw Material
1) Popped Amaranth Seeds
Amaranth seeds / Amaranth is high in protein and has abundant of nutrients like calcium,
iron, magnesium, phosphorus and potassium. Also, this is the only grain to have vitamin
C. It also has lysine, an amino acid that helps to absorb calcium. It can reduce the risk of
osteoporosis (Rachael Link et al, 2018).
High in iron, this grain also making it suitable for children and older individuals who may
be more susceptible to allergies and infections has a positive impact on anemic patients.
The vitamin A in it improves vision and prevents night blindness. Zinc, a mineral known
to boost your immune system, is found in this grain.

16
With vital minerals and vitamins in place like iron, folate, selenium, etc., this royal grain
ensures that your skin and hair shines with good health. This whole grain is full of fibre,
ensuring that you stay satiated for a longer duration. It slows absorption of sugar and
even aids digestion. Moreover, the amino acid – lysine also metabolize fatty acids. Gluten
free is another added advantage of this ingredient, making it fit for consumption for
almost everyone.
2) Oats
Oats contain several components that have been proposed to exert health benefits. The
primary type of soluble fiber in oats is beta-glucan, which has been researched to help
slow digestion, increase satiety, and suppress appetite. Beta-glucan can bind with
cholesterol-rich bile acids in the intestine and transport them through the digestive tract
and eventually out of the body. Whole oats also contain plant chemicals called phenolic
compounds and phytoestrogens that act as antioxidants to reduce the damaging effects of
chronic inflammation that is associated with various diseases like cardiovascular disease
and diabetes [Hrefna Palsdottir et al, 2016].

17
Oatmeal contains both types and has the largest proportion of soluble fiber of any grain in
the form of beta-glucan. The soluble fiber in oatmeal has been shown to decrease low
density lipoprotein (LDL) cholesterol or “bad cholesterol” by 10-15%, particularly when
consumed as part of a low-fat diet. Studies show fiber can also decrease risk of high
blood pressure and reduces risk of mortality from cardiovascular disease. The water
soluble properties of beta-glucan help control blood sugar by slowing down digestion
time, which can help diabetics achieve better glycemic control and prevent insulin
resistance.
100gmoatmeal contains about 167 calories, 4 grams of fiber (about half soluble and half
insoluble), and 6 grams of protein. In addition to fiber, oatmeal is rich in thiamin,
magnesium, phosphorus, zinc, manganese, selenium, and iron (Kumar V et al, 2012).
3) Flax seeds
Flax seeds are good sources of many nutrients. Their health benefits are mainly due to
their content of omega-3 fats, lignans and fiber. They are a rich source of alpha-linolenic
acid (ALA), a mostly plant-based omega-3 fatty acid. Animal studies have shown that the
ALA in flax seeds prevented cholesterol from being deposited in the blood vessels of the
heart, reduced inflammation in the arteries and reduced tumor growth. Flax seeds are a
rich source of the omega-3 fatty acid ALA. Plant-based ALA fatty acids are proven to
have heart health benefits and are linked to a lower risk of stroke. Flax seeds contain a

18
group of nutrients called lignans, which have powerful antioxidant and estrogen
properties (Adda Bjarnadottir et al, 2019).
Consumption of flax seeds result in reduction of the cholesterol level, and good for heart
health. It reduces LDL from the blood, avoids the risk of increasing blood pressure, and
maintains the smooth functioning of the circulatory system. Apart from these, research
studies say, it helps to reduce the diabetes, also reduce the tumor cancer formation in the
body.
4) Peanuts
Peanuts are an especially good source of healthful fats, protein, and fiber. They also
contain plenty of potassium, phosphorous, magnesium, and B vitamins. Despite being
high in calories, peanuts are nutrient-rich and low in carbohydrates. The mixture of
healthful fats, protein, and fiber in peanut means they provide nutritional benefits and
make a person feels fuller for longer. This makes peanuts a healthful, go-to snack when
people compare them with chips, crackers, and other simple carbohydrate foods (Atli
Arnarson et al, 2019).

19
Fatty acids are an essential part of every diet. Most of the fat in peanuts is
monounsaturated and polyunsaturated fatty acids, which are a healthful type of fat.
Peanuts are a good source of dietary fiber. Fiber is a heart-healthful nutrient. The AHA
report says that eating fiber-rich foods improve blood cholesterol levels and lower the
risk of heart disease, stroke, obesity, and type 2 diabetes. Peanuts help control blood
sugar levels because they are relatively low in carbohydrates, but high in protein, fat, and
fiber. Fiber slows down the digestive processes, allowing a steadier release of energy, and
protein takes longer to break down than simple carbohydrates.
5) Jaggery
The carbohydrate content of jaggery is around 98%, while its sugar content is 97%. 10
grams of this unrefined sugar offers 38 calories. Jaggery comes in colors ranging from
dark brown to golden brown and consists of 20% invert sugars, 20% moisture and 50%
sucrose. It is also effectively combined with coconut, peanuts, white sugar and
condensed milk.
One of the most popular advantages of jaggery is that it possesses the ability of purifying
blood. If consumed regularly, jaggery goes a long way in cleansing blood and in leaving
the body healthy. It also helps in preventing different blood disorders and diseases by
boosting the count of hemoglobin. Jaggery also boosts immunity and thus helps in the
prevention of different blood-related problems.

20
Jaggery is quite rich in folate and iron contents and therefore it helps in the prevention
of anemia. It also offers instant energy preventing weakness and fatigue of the human
body. Jaggery is packed with minerals and antioxidants like selenium and zinc and these
help in preventing free-radical damage. These minerals and antioxidants also help in
boosting the body’s resistance to different infections.
6) Ghee
Ghee is primarily a fat and is rich in short-chain fatty acids and essential fatty acids,
linolenic acid and arachidonic acid. Ghee also contains fat soluble vitamins like vitamins
A, D, E and K, trace elements like copper and iron and carotenoids.
Every 100 grams of ghee, you can find 100 grams of fat, which means it has no protein
and no carbohydrates. Out of this fat content, ghee is primarily saturated fat, with 60
grams of saturated fat per 100 grams. This amount of ghee also has 2,000 IU of vitamin
A.

21
Ghee is a form of saturated fat. Unlike many other cooking fats, ghee is incredibly rich
with fatty acids that get converted directly into energy. The ratio of omega-3 to omega-6
fatty acids are considered ideal in pure ghee.
7) Chocolate
Chocolate comes from the cacao beans and is rich in health-promoting
flavanol phytonutrients. Dark chocolate contains triple the amount
of antioxidants compared to milk chocolate. The best way to reap the benefits of cacao
beans is to choose cocoa powder, which does not contain fat or sugar. Even dark
chocolate contains some sugar and fat, in the form of cocoa butter, which is one of the
few plant fats that can raise cholesterol.

22
Consumption of cocoa products has been associated with a decreased risk
of cardiovascular disease and stroke. The phytonutrients packed in cocoa powder may
lead to lower blood pressure and LDL levels, while boosting HDL levels and immune
function. Chocolate intake can also help open up coronary arteries, improve the ability of
veins in the eyes to dilate, improve blood flow to the kidneys, lead to improvements
in peripheral artery disease, and may even combat the effects of aging (Rawat et
al.,2015).

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Table 7.1 Raw material requirement withtheir costs
Sr. No. Material description Cost per kg
Amount
required per
month (kg)
Total cost
1 Jaggery 50 400 20,000
2 Popped amaranth seeds 160 50 8,000
3 Oats 90 100 9,000
4 Peanuts 80 100 8,000
5 Flax seeds 160 75 12,000
6 Melon seeds 200 75 15,000
7 Chocolate 170 170 28,900
8 Desi Ghee 450 30 13,500
9 Primary Packaging 270 15 4,050
10
Secondary packaging
boxes
30 10 300
11 Caustic & Nitric for CIP 50 10 500
Total 1,19,250
This small amount of raw material is easily available at the city market. We are directly
buying this material from local traders in the market, at reasonable price.

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CHAPTER 08
DETAILS OF PROCESSING EQUIPMENT’S AND
MACHINERY
Equipment are the heart of any food processing industry. We have used various
equipment’s for the production of aloha snack bar.
Table 8.1 Processing equipment
Sr.
No.
Name of
equipment
Function Capacity
No. of
pieces
required
Cost in Rs.
1
Planetary
Mixer
Mixing of dry
ingredients
20 kg 1 46,000
2
Kettle with
Agitator
Preparation of jaggery
syrup by application of
heat and also for mixing
50 kg 1 55,000
3 Cutter Cutting of bars in shape - 1 8,000
4
Automatic
Packaging
Machine
Packing of bars in
laminate
70-130
bars/ min
1 30,000
5 Trays
Spreading of hot
mixture for bar
preparation
- 12 24,000
6
Weight
Balance
Weighing materials as
per the formulation of
recipe and weighing of
final product
100g-50
kg
1 10,000
Total 1,73,000

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8.1 Suppliers
 Shreeram Engineers, 32,Nr Nika Tube Char Rasta, Shri Hari Darshan Industrial Park,
Ramio GIDC Vatwa Ahmedabad - 382449, Gujarat, India.
 Khushbu Lal Ganga, Midas 315 FafadihRaipur - 492001, Chhattisgarh, India.
 Tejas Panchal No. 49, Chirag Diamond Estate,Opposite KarnavatiBikes Bapunagar
Ahmedabad - 380024, Gujarat, India.
8.2 Equipment images
Figure 8.1 Weighing balance Figure 8.2 Trays
Figure 8.3: Cutter

26
Figure 8.4 Planetary Mixer
Figure 8.5 Auomatic fillpack machine

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CHAPER 09
SOURCES OF FIXED & VARIABLE CAPITAL
The industry is a small scale industry and the monetary requirements of the fixed capital
are met by the contributions of the members of the partnership.
The variable expenditure incurred by the industry is paid from the income of the firm. No
loans or any other financial is needed.

28
CHAPTER 10
PRODUCT MANUFACTURED
On the basis of the market survey we conducted, there was a demand for snack bars and
was decided to formulate a snack bar with basic ingredients like amaranth, peanuts and
jaggery referring to an amaranth chikki available in market and other nutritious
ingredients like flax seeds, melon seeds, oats, peanuts to improve nutritional value of
snack bar. From nutrition point of view, addition of flax seeds, oats, and melon seeds
justifies higher energy value, dietary fibres and saturated fats compensating requirement
of snack meal. While choosing a sweetner, jaggery shows many health benefits over
sugar and fewer calories as compared to artificial sweeteners. During experimental trials,
the hard texture of the snack bar lead to revision of ingredients with addition of ghee
while making jaggery syrup that enhances softness and flavour. As sensory parameters
like flavor and taste play important role in marketing of product, chocolate in liquid form
was incorporated in recipe.
10.1 Trial 1
Table10.1 Ingredients used in Trial 1
Sr.
No.
Ingredients
Formulations (g/100 g)
A B C
1 Popped amaranth seeds 5 5 5
2 Oats 10 10 10
3 Peanuts 10 10 10
4 Flax seeds 7.5 7.5 7.5
5 Melon seeds 7.5 7.5 7.5
6 Jaggery 40 45 50
7 Chocolate 17 12 7
8 Ghee 3 3 3

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Table 10.2Different Samples in Trial 1
Sample
No.
Description Problems
A
It contains less jaggery and more
chocolate
No problem in taste, but it was brittle
and easy to break
B
It has a medium amount of jaggery
and medium amount of chocolate
Problem of aftertaste may be due to
more jaggery content and slightly
suppressed chocolate taste
C
It has a high amount of jaggery
with lesser amount of chocolate
Jaggery dominating taste over
chocolate hence tasted like chikki
10.2 Trial 2
On the basis of problems occurred in 1st trial changes are made in formulation of sample
A to improve texture with respect to brittleness and three new samples were prepared in
Trial 2.
After fixing sweetness, we want to take test for the texture acceptance of bar. So, we
taken a trial by variating the form of peanuts in bar, like coarse peanuts, grounded and
peanut butter. As we know, as we going reduces sizes of peanuts, it will get smoother and
increase moisture in product vice-versa.
Table. 10.3Ingredients used in Trial 2
Sr. No. Ingredients Formulations (g/100 g)
S1 S2 S3
1 Amaranth 5 5 5

30
2 Oats 10 10 10
3 Peanuts
10
(Coarse)
10
(Ground)
10
(Peanut butter)
4 Flax seeds 7.5 7.5 7.5
5 Melon seeds 7.5 7.5 7.5
6 Jaggery 40 40 40
7 Chocolate 17 17 17
8 Ghee 3 3 3
S1: Snack bar with coarse peanuts
S2:Snack bar with ground peanuts
S3: Snack bar with peanut butter
10.3 Sensory Evaluation
The sensory evaluation of different organoleptic properties, i.e. color, aroma, texture,
taste, appearance and overall acceptability was carried out by semi-trained panelists on 9
point Hedonic scale. The average score was calculated for individual organoleptic
properties.
The samples prepared in Trial 2 (S1, S2 and S3) were evaluated for sensory characteristics
(Color, aroma, texture, taste, appearance and overall acceptability) and compared with
market sample (Nutritious amaranth chikki) to justify sensory acceptability of Aloha
snack bars.
Hedonic scale:
9 = Like extremely 1 = Dislike extremely
8 = Like very much 2 = Dislike very much
7 = Like moderately 3 = Dislike moderately

31
6 = Like slightly 4 = Dislike slightly
5 = Neither like nor dislike
Table 10.4 Sensory characteristics of Snack bar (Average score)
Sensory
characteristics
Market
Sample
S1 S2 S3
Colour 8 8.0 8.0 7.0
Aroma 9 7.0 7.0 7.0
Texture 9 7.0 7.0 8.0
Taste 8 6.0 9.0 7.0
Appearance 8 7.0 8.0 7.0
Overall
acceptability
8.4 7.0 7.8 7.2
Fig. 10.1 Sensory evaluation of snack bar
0
1
2
3
4
5
6
7
8
9
10
Colour Aroma Texture Taste Appearance Overall
acceptability
THEDDONIC
SCALE
PARAMETERS
S1
S2
S3
MS

32
The results from sensory analysis showed more overall acceptability score for sample S2
(Ground peanuts) as compared to other samples. It had better taste and desirable colour
and appearance than the rest snack bar samples. The sample S1 (Coarse groundnut) was
slightly behind S2, its colour was satisfactory, but it was poor in taste. Sample S3 which
was prepared using peanut butter had a smooth and preferable texture as compared to
other samples. This may be due to high moisture content of peanut butter, which made it
more susceptible to for microbial growth. Hence, it was decided to manufacture sample
S2 as it has better taste with a good visual appeal and was most preferred by sensory
panel.

33
CHAPTER 11
PRODUCT MANUFACTURING PROCESS
Table 11.1 Final formulated recipe for 100g Snack bar
Sr. No. Ingredients Amount (g)
1 Amaranth 5
2 Peanuts 10
3 Oats 10
4 Flax seeds 7.5
5 Melon Seeds 7.5
6 Jaggery 40
7 Chocolate 17
8 Ghee 3
11.1 SnackbarManufacturing Process
The process flow chart and pictorial representation for preparation of snack bar are
presented below.
1. Receiving of ingredient: Raw material, which was purchased from the local market
was pre-processed for preliminary cleaning operations and checked for any
impurities, quality, and sensory attributes. If any impurities were detected, it was
cleaned.
2. Weighing of all ingredients: All ingredients were weighed as per the formulation
tabulated in Table 9.1.

34
3. Roasting and mixing of dry ingredients : Puffed amaranth and roasted peanuts
were used in snack bars. Peanuts were de-skined and ground to coarser form.
No roasting was carried out for oats, flax seeds, melon seeds. All dry ingredients
were mixed in planetary mixer uniformly.
4. Preparation of syrup: Ghee was melted in heating kettle to which jaggery pieces
were added along with little water to melt it easily. This mixture was then heated till
complete melting of jaggery pieces. The end point of syrup was decided by cold
water dropping test, where few drops of syrup dropped in cold water produced soft
balls in it. Chocolate is added just a few seconds before the addition of all the dry
ingredients.
Preparation of syrup
5. Mixing of dry ingredients with syrup: After the syrup was ready, dry ingredients
were added to syrup and uniform mixing was carried out with help of planetary
mixer.

35
Uniform mixing of dry ingredients with syrup
6. Preparation of bars: The hot mixture was removed in greased trays and spreaded in
sheet. Care taken while spreading the mixture as it needs to be uniformly thick, so
every bar gets nearly equal weight and size. After cooling, bars were cut by using
cutters in pre-calculated sizes.
Mixture removed in trays
7. Packaging: The prepared bars were removed from trays, and packed with
automatic packaging machines.
8. Labelling: After packaging the sticker label is placed on it manually.
Bars cut in trays

36
Label on the bar
9. Storage: The packed bars were stored at cool and dry place. Secondary
packaging of the snack bars was carried out to keep the finished product safe
from accidental damages. There is no need of refrigerated storage because less
moisture content in bars results in more shelf life.
Bars stored at room temperature

37
Weighing of all the ingredients
(Amaranth, flax seeds, oats, peanuts, melon seeds,
ghee, chocolate and jaggery)
Roasting and mixing of dry ingredients Preparation of syrup by
melting ghee and jaggery
↓
Mixing of dry ingredients with syrup
↓
Spread uniformly in trays
↓
Cutting as per size
↓
Cooling
(Room Temperature)
↓
Packaging (APM machine) and labelling
↓
Storage
(Room temperature)
Fig 11.1. Process flowchart for preparation of Aloha snack bar

38
CHAPTER 12
CLEANING AND SANITIZING OPERATION
12.1 Current Good Manufacturing Practices (GMP)
Quality maintenance is an important factor for any food industry. Quality is maintained
not only by using quality raw material, but also subsequent hygienic handling. These
handling practices are called current good manufacturing practices.
GMP plays an important role in quality control. GMP is defined by WHO ( World Health
Organization ) as “ the part of quality assurance which ensures the product are constantly
produced and controlled to the quality standard appropriate to their intended use as
required by marketing authorization.”
12.1.1 Principles of GMP:
1. Writing procedure
2. Following written procedure
3. Documenting for traceability
4. Designing facility and equipment
5. Maintaining facility and equipment
6. Cleanliness
7. Component control
8. Auditing for compliances

39
12.1.2 Overview of GMP:
A) General provision
Personal: The plant management needs to take all reasonable measures and
precautions.
a) Disease control: A diseased person should not be allowed in the processing area, in
order to avoid contamination.
b) Cleanliness: Hygiene and cleanliness should be maintained by ensuring that all
persons working in direct contact with food, contact surfaces and packaging material
wear aprons and hair caps, and wash their hands thoroughly. The personnel are also
asked to remove all jewelry and other objects that might fall during food preparation.
B) Building and facilities
a) Plant and ground: The floor of the food plant under the control of the operator shall
be kept in good condition. Plant building and structure should be of suitable size.
Plant should be constructed in such a manner that the floor wall may be adequately
cleaned and maintained. Adequate lighting and ventilation should be provided.
b) Sanitary operations: Building, fixtures and other physical facilities of the plant
should be kept in good sanitary conditions.
c) Facility and control: Hand washing facilities should be adequate and furnished with
running water at suitable temperatures.
C) Equipment's and Utensils
All the plants equipment's should be adequately cleaned and properly maintained.
D) Production and Control
a) Raw material and other ingredients: The raw material is inspected and ensured that
it is clean and suitable for processing.

40
b) Manufacturing operations: All food manufacturing should ensure packaging and
storage is conducted under such a condition and control, in order to minimize the
potential for growth of microbes.
c) Warehousing and Distribution: Storage and transportation of finished product should
be under controlled conditions so that the product is protected against physical,
chemical and microbiological contamination as well as deterioration of food.
 Cleaning and sanitizing operations
Sanitizer as a substance was used to reduce microbial load to an acceptable limit.
Various Sanitizers used in bakery plant are:
• Hot water
• Acids
• Chemicals
 Equipment cleaning
1) Plenty of potable water is used to clean equipment.
2) Appropriate detergents are used for bakery equipment.
3) Acceptable cleaning tools such as brushes, foam applicators, sprays are used.
4) Sanitizing solutions will kill microbes.
 Personal hygiene
1) Protective outer clothing: Lab coats are used during analysis and clean clothes were
worn during processing.
2) Footwear: Footwear is used in bakery plants during processing and working with
electrical appliance.

41
3) Hygiene: To maintain hygiene conditions, nails should be trimmed, and hands should
be washed using sanitizer.
4) Head caps: Caps should be used to cover hairs.
 Process Hygiene
1) Floors must be cleaned properly by using detergents.
2) Windows should be closed with mesh to avoid entry of insects inside the plant.
3) Clean air must be present in the processing area.
4) Personal hygiene is important during processing.

42
CHAPTER 13
QUALITY CONTROL AND NUTRITIONAL ANALYSIS
13.1 Quality
It is defined as a composite of those characteristics that differentiate individual units of
product and have significance in determining the degree of acceptability of that unit by
buyer.
13.2 Quality Control
It is defined as maintenance of quality at a certain level and tolerance acceptable to the
buyer while minimizing the cost of production. Quality control is essential in all food
processing plants. It may be defined as maintenance of quality at a level and tolerance
acceptable to the buyer while minimizing the cost of the vendor. Quality control is an
important step in the production plan. The specific responsibility of quality control is to
ensure that the system is used to produce a standard product with acceptable quality with
respect to nutrition, purity and wholesomeness and palatability.
13.2.1 Principles of quality control
A. Raw material control
B. Process control
C. Finished product inspection
A) Raw material control
Before buying raw materials in bulk, food manufacturer generally examines the9 samples
to make sure that it fulfills the factory's specifications. Raw materials examined for
different parameters and it varies with nature and type of ingredients.

43
B) Process control
All treatments given during processing are standardized, ingredients used in the correct
amounts, accurate method of preparation and mixing are employed, and checks are made
on the containers used to make sure that they are sound. Satisfactory hygienic conditions
are also maintained during processing. Sanitization is done during processing, mixing
(proper proportion) ingredients and regulating kneading time.
C) Finished product inspection
It is carried out to determine to what extent the desired quality specifications have been
achieved. Some tests are performed to check certain properties which are related to
palatability and acceptability of the product. GMP, HACCP are also important aspects of
quality control.
13.3 Chemical Analysis of Aloha Snack Bar
13.3.1 Estimation of carbohydrate by Anthrone method
Principle:
The Anthrone reaction is the basis of rapid and convenient method for the determination
of hexoses, aldopentoses and hexouronic acids either free or present in polysaccharides.
Carbohydrates are dehydrated by Conc. sulphuric acid to form furfural. Furfural
condenses with Anthrone to form a blue-green colored complex which is measured
calorimetrically at 630 nm.
Equipment:
Water bath, Centrifuge, Spectrophotometer, Weighing balance, Refrigerator
Material:
Test tubes, beaker, test tube stand, and sample

44
Reagent:
1) Hydrochloric acid
2) Anthrone reagent –Dissolve 200mg Anthrone in 100ml ice cold 95% Sulphuric acid.
Prepare fresh before use.
3) Standard glucose solution (stock solution) –Dissolve 100mg in 100ml water,
Working standard (10ml of stock diluted to 100ml with D/W. Store refrigerated after
addition of few drops of toluene.)
Procedure:
1) Weigh 100mg of the sample into a boiling tube.
2) Hydrolyze by keeping it in a boiling water bath for 3 hours with 5ml of 2.5N
Hydrochloric acid and cool to room temperature.
3) Neutralize it with solid sodium carbonate until the effervescence ceases.
4) Make up volume to 100ml and centrifuge.
5) Collect the supernatant and take 0.5 and 1ml aliquots for analysis.
6) Prepare the standard by taking 0, 0.2, 0.4, 0.6, 0.8 and 1 ml of working standard.
Make up the volume to 1ml in all tubes, including the sample tubes by adding D/W.
7) Then add 4ml of Anthrone reagent.
8) Heat for 8 min in a boiling water bath.
9) Cool rapidly and read the green to dark color at 630nm.
10) Draw a standard graph by plotting concentration of the standards on the X-axis Vs
absorbance on Y-axis.
11) From the graph calculate the amount of carbohydrate present in the sample tube.

45
Formula:
Amount of CHO present(%mg)=
sugar value from graph(mg)
Aliquot sample used (
0.5
1ml
)
×
total volume of extract(ml)
weight of sample(mg)
×100
13.3.2 Determination of ash content
Principle:
The sample is ignited at to burn off all organic matter. The inorganic material which does
not volatilize at that temperature is called ash.
Equipment’s:
Muffle furnace and weighing balance
Material:

46
Silica crucibles, Desiccators and Sample
Method:
1) Weigh the sample and put it into crucible.
2) Place clean crucible in muffle furnace at 550˚C for 1 hour.
3) Transfer crucible from furnace to desiccator and cool to room temperature.
4) Weigh as quickly as possible to prevent moisture absorption.
5) Weigh by difference 2.0g of sample into tarred silica crucible.
6) Place in a muffle furnace and adjust the temperature at 550ºC for 6 hours.
7) Transfer the crucible to desiccators and cool to room temperature.
8) When cool, weigh crucible as quickly as possible.
Formula:
Ash(%) =
weight of ash
weight of sample
× 100
13.3.3 Estimation of crude fiber
Principle:
During the acid and subsequent alkali treatment, oxidant hydrolytic degradation of the
native cellulose and considerable the degradation of lignin occurs. The residue obtained
after final filtration weighted, incinerated, cooled and weighed again. The loss in weight
gives the crude fiber content.
Requirements: Food sample

47
Equipment’s: micropipette, centrifuge, refrigerator, colorimeter, water bath, weighing
balance.
Materials: beakers, test tubes, micro tips
Reagent:
1) 0.255 ± 0.005 N Standard Sulphuric Acid
2) 0.313 ± 0.005 N Standard Sodium Hydroxide
Procedure:
1) Extract 2 g of ground sample with ether or petroleum ether to remove fat (initial
boiling temperature 35˚C and final temperature, 52˚C).
2) Boil 2 g of dried sample with 200 ml of Sulphuric acid for 30 min with bumping
chips.
3) Filter through muslin cloth and wash with boiling water until washings are free of
acid.
4) Boil the residue with 200ml of Sodium hydroxide for 30 min.
5) Filter through muslin cloth again and wash with 25 ml of boiling Sulphuric acid, three
50ml portions of water and 25 ml of alcohol.
6) Remove the residue and transfer to pre- weighed ashing dish (‘W1’ g).
7) Dry the residue for 2h at 130ºC and cool in desiccator and weigh (‘W2’ g)
8) Ignite for 30 min at 600ºC.
9) Cool in a desiccator and reweigh (‘W3’g).
Formula:
% Crude Fiber content = (W2 − W1) × 100
Weight of sample (g)

48
13.3.4 Determination of calcium
Calcium is precipitated as calcium oxalate. The precipitate is dissolved in hot dilute
Sulphuric acid and titrated with standard potassium permanganate.
Reagents:
1) Ammonium oxalate –saturated solution.
2) Methyl red indicator: Dissolve 0.5 g methyl red in 100 ml of 95% alcohol.
3) Dilute acetic acid:-1+4.
4) Dilute ammonium hydroxide-1+4
5) Dilute Sulphuricacid-1+4: add acid to water slowly and with constant stirring. Cool
and make up to volume.
6) 0.1N Potassium permanganate
7) 0.01N Potassium permanganate - Working standard: Dilute 10 ml of 0.1 N Potassium
permanganate solutions to 100 ml with water (1 ml = 0.2 mg of Ca).Prepare fresh
solution before using.
Procedure:
1) An aliquot (20 to 100 ml) of the ash solution obtained by dry ashing to a 250 ml
beaker.
2) Pipette Add 25 to 50ml of water, if necessary. Add 10ml of saturated ammonium
oxalate solution and 2 drops of methyl red indicator.
3) Make the solution slightly alkaline by the addition of dilute ammonia and then
slightly acidic with a few drops of acetic acid until the color is faint pink (pH 5.0)
4) Heat the solution to the boiling point. Allow to stand at room temperature for at least
4 hr.

49
5) Filter through Whatman No. 42 filter paper and wash with water, till the filtrate is
oxalate free. (Since Hydrochloric acid has been used for preparing the original ash
solution, it is convenient to test for the absence of chloride using Silver nitrate.)
6) Break the point of the filter paper with platinum wire or pointed glass rod. Wash the
precipitate first using hot dilute Sulphuric acid (1+4) from washed bottle into the
beaker in which the calcium was precipitated.
7) Then wash with hot water and titrate while still hot with 0.01 N Potassium
Permanganate the first permanent pink color.
8) Finally, add filter paper to solution and complete the titration.
Formula:
Titre ×0.2 × Total volume of ash solution × 100
Calcium mg/100g=
Volume taken for estimation × Wt. of sample taken for ashing
13.3.5 Determination of fat
Principle:
Ether is continuously volatized, condensed and then allowed to pass through the sample
to extract the ether soluble materials. When the process is completed, the ether is
distilled, collected in another container, remaining crude fat is dried, weighed and percent
fat is calculated.
Reagent:
Pet. Ether /ethyl ether /hexane
Sox -Tron operational procedure:

50
1) Rinse all the collection vessels and place them in oven with the temperature about
100 ºC and also the samples.
2) If all moisture were removed from the collection vessels them in desiccator to bring
to room temperature.
3) Now weigh the empty collection vessels and let the weight be W1. These initial
collection vessels weight.
4) Now insert the thimble in the thimble holder and place it on the collection vessels.
5) Weigh the sample and transfer them to the thimble. Let the sample weight may be 2.5
gm to be W.
6) Pour the solvent in the collection vessels and the volume may be 90 ml.
7) Load all the collection vessels in the system .Switch on the system and set boiling
point of solvent as the boiling temperature. The boiling temperature may be 100ºC
to200ºC more than the solvent’s maximum boiling point.
8) Leave the process about 45 to 60 min. After the process time, increase the
temperature to solvent recovery temperature.
9) Now do the rinsing about 2 times in order to collect the remaining fat that may
present in the sample. Now takeout all the collection vessels from the system and put
them in a hot air oven.
10) After 15 min, take out all the beakers and place them in a desiccator about 5 min.
11) Take out all thimble holders and weigh the collection vessels. This is the final weight
of the collection vessels W2. By submitting W, W1, and W2 in the following formula,
the amount of fat present in the sample can be calculated.
Formula:
Fat (%on dry basis) = (W2 –W1)×100
Weight of sample (W)

51
Where, W= weight of sample
W1= weight of empty collection vessel
W2 = final weight
13.3.6 Determination of Nitrogen/Protein
Principle:
The sample is digested with Conc. sulphuric acid in the presence of a catalyst to convert
the nitrogen in protein or any other organic material to ammonium sulphate. By steam
distillation of this salt in the presence of a strong alkali, ammonia is liberated and
collected in boric acid solution as ammonium borate which is estimated against a
standard acid by titration. On an average most proteins have 16% nitrogen in their
composition. In other words, 1 mg nitrogen equal 6.25 mg protein. Thus, by finding out
the amount of ammonia formed from a known amount of sample, one can calculate the
protein present (1ml of 0.1 N acid = 1.401 mg N).
Reagent:
1) Mixed indicator: Prepare 0.1 % bromocresol green and 0.1% methyl red indicator in
95% alcohol separately. Mix 10 ml of bromocresol green with 2 ml of methyl red
solution
2) Catalyst for digestion: Mix 2.5 gm of powdered selenium dioxide, 100 gm
potassium sulphate and 20 gm of copper sulphate.
3) (30%) Sodium hydroxide: Dissolve 150 gm of sodium hydroxide pellets in 350 ml
D/W.
4) 0.01 N Hydrochloric acids.
5) 2% Boric acid solution: Dissolve 4 of H3BO3 in warm water 7 dilute to 100ml.
Digestion system:

52
1) Main Heating block
2) Tube inserts Rack
3) Tube Support Rack
4) Manifold holding rack
5) Manifold holding support rack
6) Kjeldhal Suction pump
7) Digestion tube
Procedure:
1) Preheat the digestion system up to 300ºC.
2) Take a required amount of sample in the digestion tube.
3) Now add 3 gm of catalyst mixture and finally add 10 ml of conc. Sulphuric acid. Lead
the tubes in the digestion block along with the manifolds.
4) Ensure the manifolds are fitted properly.
5) Switch on the scrubber system immediately.
6) Ensure any frothing of sample are there if the behavior is normal than rise the
temperature to 420 ºC.
7) Leave the tubes in the block for 1 hr. After an hour ensure the color of the sample
turned to bluish green than remove the tubes and place in the cooling stands.
8) Transfer the digest to distilling flask with 100 ml of ammonia free water, and add
large piece of granulated zinc.
9) Take 20 ml of boric acid in receiving flask, add few drops of mixed indicator, place
below condenser and ensure that delivery tube dips in boric acid solution.

53
Carry on the distillation till the volume of boric acid solution in the receiving flask is
doubled.
10) Titrate the distillate using 0.01 N Hydrochloric acid.
Formula:
% Nitrogen = (Sample titre – blank titre) × Normality of HCL ×14×100
Weight of sample (g) ×1000
Protein % = Nitrogen % × 5.46
13.3.7 Determination of Moisture
Principle: The moisture of the sample is lost by volatilization caused by heat. The
amount of material left after the removal of the moisture is the dry matter.
Equipment:
Oven 150˚C and Weighing balance
Materials:
Petri plates, Desiccators and Sample
Method:
1. Wash the Petri plates with a detergent
2. Dry the Petri plates at 150˚C in oven for 1 hr.

54
3. Place in a desiccator for cooling and weigh.
4. Weigh the sample into a weighed dish.
5. Place it in 150˚C oven overnight (with lids open until a constant weight loss.)
6. Remove the dishes, place in desiccator and cool.
7. Remove from desiccators and weigh as quickly as possible.
Formula:
Moisture content (%) = Weight of fresh sample – weight of dry sample × 100
Weight of fresh sample
Table 13.1 Nutritional Composition of Aloha Snack bar
Sr. No. Nutritional
Parameters
Value Analytical Method
1 Moisture (%) 11.8 Hot air oven
2 Carbohydrate (%) 49.5 Anthrone
3 Fat (%) 8.16 Soxhlet
4 Protein (%) 12.3 Kjeldhal
5 Ash (%) 1.92 Muffle furnace
6 Crude fiber (%) 16.7 Digestion
7 Calcium (mg) 178 Titration
8 Iron (mg) 12 Titration

55
CHAPTER 14
LEGAL ASPECTS
14.1 Standard of Weight and Measure Act (1976)
1. Effective legal control on weight, measures.
2. Control on weighing and measuring instruments in industrial production.
3. Establishment of weights and measures based on SI unit, as adopted by the
CGPM (General Conference on Weights and Measures) and recognized by OIML
(International Organization of Legal Metro-logy).
4. To prescribe specification of measuring instruments used in commercial
transaction, industrial production a measurement involved in public health and
human safety.
5. To give power to inspector for search, seize and forfeiture of non- standard weight
or measure.
6. Control and regulation of export and imports of weight and measures and the
industry follows the following laws of commodities in packed formed.
14.2 Food Safety and Standard Act (2006)
1. To regulate and monitor the manufacturing, processing, distribution sale, imports,
exports of food so as to ensure safe and wholesome food.
2. To specify:
a) The standards and guidelines related food articles and an appropriate system
for enforcing various standards notified under this act.
b) The limits for use of food additives, crop, contentment, pesticides residues , of
veterinary drugs, heavy metals, processing aids, mycotoxins, antibiotics and
pharmacological active substance and radiation of food.
c) The Mechanism and guideline of certification bodies engaged in certification
of food safety management system for food business.

56
d) The method of sampling analysis and exchange of information among
enforcement.
e) Food labelling and standards including claims on health, nutrition, and
special.
3. Dietary uses and food and food category and systems of food.
4. To promote general awareness about food safety and food standards.
5. To prevent the exposure of information to third parties.
14.3 Environmental Protection Act (1986)
1. Protection and improvement of human environment and prevention of hazards to
human beings and other living creatures.
2. Regulation of discharge of environmental pollutants and handling of hazardous
substances.
3. Speedy response in events of accidents threatening environment and punishment
to those who endanger human environment, safety and health.
4. To co-ordinate the activities of the various regulatory agencies already in
existence.

57
CHAPTER 15
HAZARD ANALYSIS AND CRITICAL CONTROL POINT
(HACCP)
The Hazard Analysis Critical Control Point (HACCP) program is a preventive approach to
consistent safe food production. This program is based on two important concepts of safe food
production-prevention and documentation. The major thrusts of HACCP are to determine how
and where food safety hazards may exist and how to prevent their occurrence. The important
documentation concept is essential to verify that potential hazards have been controlled.
HACCP has been recommended and/or required for use throughout the food industry and is the
basis for federal food inspection in the USA. The HACCP concept was developed in the
1950’s through the National Aeronautics and Space Administration (NASA) and Natick
Laboratories for use in aerospace manufacturing under the name ‘Failure Mode Effect
Analysis.’ This rational approach to process control for food products was developed jointly by
the Pillsbury Company, NASA, and U.S. Army Natick Laboratories in 1971. HACCP is a
technique which assesses the flow of food through the process, provides a mechanism to
monitor these operations frequently and to determine the points that are critical for the control
of foodborne disease hazards. A hazard is the potential to cause harm to cause harm to the
consumer. A critical control point (CCP) is an operation or step by which preventive or control
or step by which preventive or control measures can be exercised that will eliminate, prevent,
or minimize a hazard. The HACCP concept is divided into two parts: (1) hazard analysis and
(2) determination of critical control points. It aims to identify possible problems before they
occur and establish control measures at stages in the production process that are critical to
product safety. One of the purposes of HACCP is to design safety into the process, thereby
reducing the need for extensive microbiological testing of inline samples and finished products.
There can hardly be HACCP without Good Manufacturing or Management Practices (GMP).
GMP is a description of all the steps in a processing facility, while HACCP is a documentation
that the steps important to consumer health are under control. Sanitation standard operating

58
procedures (SSOPs) are also a needed pre-requisite to HACCP. Pre-requisites are advisory not
mandatory. GMPs differ from HACCP in a number of ways. First, they are not designed to
control specific hazards. Second, they do not provide methods for monitoring hazards and
third, they do not require specific recordkeeping procedures. The Hazard Analysis Critical
Control Points (HACCP) system is a logical, scientific system that can control safety problems
in food production. HACCP is now being adopted worldwide. It works with any type of food
production system and with any food. It works by controlling food safety hazards throughout
the process. The hazards can be biological, chemical, or physical.
The five preliminary steps are:
1. Bring together your HACCP resources/assemble the HACCP team
HACCP TEAM
Role in Company Plant Manager
Role in Company Procurement and Sales
Manager
Role in Company Production Manager

59
2. Describe the food product and its method of distribution.
3. Identify the intended use and consumers of the food.
4. Develop a process flow diagram.
5. Verify the diagram in the operation it is meant to represent
Applying the seven HACCP principles make up the major steps in
Writing a HACCP plan. They are-
1. Conduct a hazard analysis
2. Identify critical control points
3. Establish critical limits for each critical control point
4. Establish monitoring procedures
5 Establish corrective actions
Role in Company Quality Manager
Role in Company Quality Assurance
Role in Company HR Manager

60
6. Establish record-keeping procedures
7. Establish verification procedures
Table 15.1: Product Description
Product Name Protein and Fiber rich snack bar
Composition Amaranth, Peanuts, Oats, Flax seeds, Melon Seeds, chocolate
syrup, Jaggery, ghee.
Packaging Laminates.
Storage condition Room temperature
Who will consume All age group above 5 year
Shelf life Six months
Where it is to be sold Local Market & Retail market
Intended use Ready to eat
15.1.Process Flow Diagram:
Name of the product - Snack bars
Flowchart: Preparation of Snack bars
Weighing of all the ingredients
(Amaranth, Flax seeds, Oats, Peanuts, melon seeds,
Ghee, chocolate and Jaggery)
Roasting and mixing of dry ingredients (CCP 1) Preparation of syrup by
melting ghee and jaggery

61
↓
Mixing of dry ingredients with syrup
↓
Uniform spreading of mixture in trays
↓
Cutting as per size
↓
Cooling
(Room Temperature)
↓
Packaging ( in APM machine) and labeling (CCP 2)
↓
Storage
(Room temperature)
Table 15.2 Hazard Analysis
Step Possible hazard
Raw material receiving Low quality or sub-standard material.
Dry ingredients intake Foreign bodies in final product
Roasting and syrup preparation;
Mixing
Contact with greasy material
Unclean utensils
Packaging Increase in moisture content in the product,
improper texture
Storage Infestation

62
Methodology used to conduct hazard analysis
A. Identify and list all potential hazard associated with each process step
and post production step.
Label the hazards as B (biological), C (chemical). P(physical)
A(allergens)
B. Determine the risk (probability) of occurrence.
A. High risk is likely to happen ;A. medium risk could happen; A.
low risk, may not likely happen
C. Determine the severity of each hazard
A. Critical severity will automatically result in an unsafe product
B. Major severity may result in an unsafe product
C. Minor severity will not result in a unsafe product
D. List preventive measure to control hazard.
Likelihood of
occurrence
Severity of impact
CRITICAL MAJOR MINOR
HIGH SIGNIFICANT SIGNIFICANT NON-
SIGNIFICANT
MEDIUM SIGNIFICANT SIGNIFICANT NON-
SIGNIFICANT
LOW SIGNIFICANT NON-
SIGNIFICANT
NON-
SIGNIFICANT

63
CCP Decision Tree
Table 15.3 Hazard analysis& CCP determination of raw material:
Raw
material
Hazard
&causes
Risk Sever
ity
Preventiv
e measure
Signific
ant
Q1 Q2 Q3 Q4 C
C
P
N
o
.
Oats,
Peanuts,
amaranth,
flax seeds
and Melon
B: Chances
of presence
and growth
of yeast
&moulds,
Low major Obtain
fresh &
good
quality
material
Non-
signific
ant
NA NA NA NA N
A

64
seeds. pest
infestation.
C: Chances
of presence
of additives.
Low Majo
r
Contact
dealer
Non-
signific
ant
NA NA NA NA N
A
P ; chances of
presence of
plastic pieces
, metal debris
from
equipment’s
Low Majo
r
The
product
will pass
through
metal
detector
/magnetic
rolls.
Non-
signific
ant
NA NA NA NA N
A
A; chances of
allergens
Low Majo
r
Supplier
control
check at
reception
Non-
signific
ant
NA NA NA NA N
A
Jaggery Chances of
presence and
growth of
yeast
&moulds
from supplier
Medi
um
Mino
r
Purchase
d from
approved
supplier
and raw
material
specificati
ons
Non-
signific
ant
NA NA NA NA N
A
C: Chances
of excess
sulphur di-
oxide from
supplier.
Medi
um
Mino
r
Purchase
d from
approved
supplier
Non-
signific
ant
NA NA NA NA N
A
P : Chances High Majo Purchase Non- NA NA NA NA N

65
of presence
of extraneous
matter like
threads,
plastic pieces
, metal pieces
from supplier
r d from
approved
supplier
signific
ant
A
A : chances
of allergens
Low Majo
r
Supplier
control
check at
reception
Non-
signific
ant
NA NA NA NA N
A
Chocolate
compound
B: Chances
of presence
and growth
of yeast &
moulds.
Medi
um
Majo
r
Purchase
d from
approved
supplier
and raw
material
specificati
on
Signific
ant
NA NA NA NA N
A
C:chances of
getting
adulterants
High Majo
r
Purchase
d from
approved
supplier
Signific
ant
NA NA NA NA N
A
A; chances of
allergens
Medi
um
Majo
r
Supplier
control
Signific
ant
NA NA NA NA N
A
Process steps:
Receivin P: Chance of Low Majo Obtain Non- Y Y - - C

66
g of raw
material
s
presence of
extraneous
matter like
threads, piece
of papers
insects ,metal
piece from
supplier
r good
quality
raw
material
from
supplier
significant CP
1
Cleaning C: chances of
getting worn
out equipment
debris while
mixing
Low Majo
r
Regular
and
inspection
maintenan
ce of
equipment
Non-
significant
Y N N - N
A
P: Chances of
presence of
dirt mud,
plastic, pieces.
Chances of
falling hair
,nail, piece of
Jewellery, etc.
Mediu
m
Majo
r
Purchase
from
approved
supplier
check at
receipt
before use
passed
through
sieve
Significant
Y N N - N
A
Syrup
preparat
ion and
mixing
C: chances of
getting worn
out equipment
debris while
mixing
Low Majo
r
Regular
inspection
and
maintenan
ce of
equipment
Non-
significant
Y - - - N
A
P: Chances of Low Mino Purchase Non- Y N Y N C

67
presence of
dirt mud,
plastic, pieces.
Chances of
falling hair
,nail, piece of
jewellery, etc.
r from
approved
supplier
significant CP
2
Sheeting
and
mouldin
g
C: chances of
getting worn
out equipment
debris while
mixing
Low Mino
r
Regular
inspection
and
maintenan
ce of
equipment
Non-
significant
Y N N - N
A
P: Chances of
presence of
dirt mud,
plastic, pieces.
Chances of
falling hair
,nail, piece of
jewellery,
bindi etc.
Low Mino
r
Regular
inspection
and
maintenan
ce of
equipment
Non-
significant
Y N N - N
A
Cooling P:non-
maintenance
of optimum
temperature
Mediu
m
Mino
r
Establishi
ng control
instrument
s and
regulating
them
regularly
Significant N
A
N
A
N
A
N
A
N
A
Packagin
g
P:chance of
presence of
Low Mino
r
Purchase
from
Non-
significant
Y N
A
N
A
N
A
N
A

68
extraneous
matter like
threads, piece
of papers
from supplier
approved
supplier
Storage B:Chances of
presence of
microbes in
store room
Mediu
m
Majo
r
Regular
fumigation
Significant N
A
N
A
N
A
N
A
N
A
C: Chances of
presence of
chemical in
store room
Mediu
m
Majo
r
Keeping
separate
section for
storage of
chemicals
in dry
storage
Significant
N
A
N
A
N
A
N
A
N
A
P: Chances of
presence of
extraneous
material like
dust , dirt etc.
Mediu
m
Majo
r
Maintenan
ce of
cleaning
Non-
significant
N
A
N
A
N
A
N
A
N
A
Process step, hazards, CC limits, monitoring procedure, deviation procedure,
HACCP record.
Process step Hazard
description
Critical
limits
Monitoring
procedure
Deviation
procedures
HACCP
Record

69
1.Receiving
of
ingredients
chance of
presence of
extraneous
matter like
threads,
piece of
papers
insects, metal
piece from
supplier
Inspection
as per given
limits in
FDA
Check
optimum
limits of
hazard
Line
operator to
Adjust the
settings.
Operators
logbook
and
quality
control
Report.
2. Mixing
dry
ingredients
with syrup
Chances of
presence of
dirt mud,
plastic,
pieces.
Chances of
falling hair,
nail, piece of
jewellery etc.
Improper
mixing of
ingredients.
Regulating
Mixing time
and proper
mixing of
ingredients.
Check
optimum
limits of
hazard
Line
operator to
Adjust the
settings.
Operators
logbook
and
quality
control
report.
3.Roasting The increase
or decrease
in
temperature
and time will
affect the
texture of the
product.
120ºC+ Check
optimum
temperature
and time
Line
operator to
Adjust the
settings.
Operators
logbook
and
quality
control
Report.

70
Chapter 16
IMPLEMENTATION OF ISO 9000 AND FOOD SAFETY
STANDARDS 22000 SERIES
Introduction
ISO 22000:2005 specifies requirements for a food safety management system where an
organization in the food chain needs to demonstrate its ability to control food safety
hazards in order to ensure that food is safe at the time of human consumption. It is
applicable to all organizations, regardless of size, which are involved in any aspect of the
food chain and want to implement systems that consistently provide safe products. The
means of meeting any requirements of ISO 22000:2005 can be accomplished through the
use of internal and/or external resources. Structure of ISO 22000: 2005 Standard. The
organization need to develop documentation meeting the compliance to the following
main requirements in the farm of Food Safety Quality Manual with sections such as
1. Policy Document
2. Procedures
3. Work instructions
Title of the Clause-
16.1. Scope ISO 22000:2005 specifies requirements to enable an organization
i. To plan, implement, operate, maintain and update a food safety management system
aimed at providing products that, according to their intended use, are safe for the
consumer,
ii. To demonstrate compliance with applicable statutory and regulatory food safety
requirements,
iii. To evaluate and assess customer requirements and demonstrate conformity with those
mutually agreed customer requirements that relate to food safety, in order to enhance
customer satisfaction,

71
iv. To effectively communicate food safety issues to their suppliers, customers and
relevant interested parties in the food chain,
v. To ensure that the organization conforms to its stated food safety policy,
vi. To demonstrate such conformity to relevant interested parties, and
vii. To seek certification or registration of its food safety management system by an
external organization, or make a self-assessment or self-declaration of conformity to ISO
22000:2005
16.2. Terms and Definition
Food safety: Assurance which does not give harmful to consumer, when food are
prepared as suitable to aim and eaten.
Food chain: A food and its components, is phases and operational serials which are
found from first production until consuming, production, operating, distribution, storage
and transport.
Food safety hazard: biological, chemical or physical elements or food situations which
can give inverse effect for health in food.
Food safety policy: Detailed commitment which means top management of organization
formal related food safety.
Final product: product which is not operated or changed in further by organization.
Flow diagram: presenting of schema and systematic of interacting and range of steps until
final product is occurred.
Control guarding: operation or action which is to guard or to remove or to be acceptable
level food safety hazard.
Prerequisite program: Suitable production should be done in hygienic ambient along
food safety and food chain, final product should be safety and it is basic requirements and
actions to consume in food safety.
16.3. Food Safety Management System (FSMS) is a network of interrelated elements
that combine to ensure that food does not cause adverse human health effects. These
elements include programs, plans, policies, procedures, practices, processes, goals,
objectives, methods, controls, roles, responsibilities, relationships, documents, records,
and resources.

72
16.4. Management Responsibilities Food safety - Our responsibilities Show all parts of
this guide
1. Food safety
2. Food hygiene
3. Food inspections
4. Report a food safety incident
2 Implementation of ISO 9000 and Food Safety Standards 22000 Series in Plant-
1. We make sure that the raw materials are safe to eat.
2. We did not add any food additives.
3. We maintained proper hygienic conditions while manufacturing.
4. We used proper packaging material that avoids microbial contamination.
5. We followed the HACCP system in our plant.

73
CHAPTER 17
PACKAGING AND LABELING
17.1 FoodPackaging: Packaging
A package provides protection for special physical, chemical, or biological agents. It may
bear a nutrition facts label and other information about food being offered for sale.
Importance
Eye catching appearance of packaging with informative label is a signal at the point of
sale to which all consumers respond positively. Packaging which appeals to more than
one senses attract greater attention, intensifies perception and stimulates interest in
buying. Packaging that can be felt, smelled and heard wins the customers favor, which
often means that he will be prepared to pay higher cost for the product. Product and
aroma protection, hygiene and tightness, environmental responsibility and practical
handling are just as important as ideas that improve comfort.
Function of Packaging
1. Physical protection
2. Barrier properties
3. Informative
4. Containment
5. Marketing
6. Security
7. Convenience
The Aloha snack bar was packed in laminate films made up with metalized film along
with polyethylene inside and polyester film on outside of package. This laminate is
suitable for snack food as metalized film has a high resistance to moisture, polyethelene
has good sealing property and polyester boasts good barrier properties to oxygen and
water with high tensile strength and good printability.

74
17.2 Labeling
Food label carries useful information to help you make good choice about food. The food
label will tell you if the food contains an additive that you may want to avoid. The
nutrition information panel helps you to compare the nutrient profile of similar product
and choose the one that suits your needs.
Labeling Rules
The industry follows the following rules regarding labeling:
1. Lettering
The size of lettering on labels is now less restricted. Lettering must be legible, i.e. clear
enough to read, and in English. Specific sized lettering is only for allergy warnings.
2. Ingredients
Ingredients have to be listed in order of quantity added from the highest to the lowest
ingredient, based on their weight when they are added. All ingredients must be listed,
including all additives that act on the finished product in any way.
3. Plant Address
The label should display the name and street address of the plant, or someone who sells
the product or someone who distributes the product.
4. Nutritional Information Panel
The packaging must have a Nutritional Information Panel (NIP). Information per 100
grams and per serving size is required for energy in kcal, proteins in grams, total
carbohydrates in grams, and total fat in grams.
There is no need for other nutritional information to be listed, unless a claim is made
about it on the packaging, such as “High fiber content”. The number of servings in the
package must also be included on the NIP.

75
5. Best Before
A properly sealed package of food, which has been stored correctly, should be of high
quality until the marked date. It must also keep any specific qualities claimed for it until
date. The best before date must be encoded, and must be shown as numbers, except for
the month and year must be readable.
6. Storage Direction
Storage directions must show how to maintain the product for shelf life.
7. Ingredient Limitations
There is a comprehensive list of food additive restrictions and maximum allowed levels
set in the new food standards.
Fig.17.1 Label design

76
CHAPTER 18
STORAGE FACILITIES
There is no any specific storage requirement since all the raw materials used are self-
stable at room temperature. Snack bar contains low moisture and packed with laminated
material, which is a good barrier against moisture. It was also packed in secondary
packages for protection against the physical damages. Care was taken not to expose it to
sunlight.
Warehouse
The plant is equipped with storage of 1000 sq. ft. which is at normal temperature with
proper shade and ventilation. The finished bars are stored at cool and dry place away
from sunlight before dispatch. No refrigerator is required or no any shelf is needed for
storage of snack bar packets.
Types of Storage
 Raw material storage: Raw material is received and stored, so further it can be used
for continuous production. Raw material firstly is tested for quality and then cleaning
is carried out and finally stored in raw material storage. Store works on policy of
FIFO.
 Finish Product Storage: The product is filled in corrugated boxes as 50 pieces per
box.

77
CHAPTER 19
COST ANALYSIS, PRODUCTION COST AND REVENUES
19.1. Project Economics
Plants have a production capacity of 40kg/day, i.e. 2,000 bars per day. The factory has 25
days of working per month. Yearly 300 days.
19.2. Fixed Cost
It is the cost which paid initially for resources, that apart from business activity, which
use for a long time.
1. Land: Production needs space of 2,500 sq. ft. In this area, 1,000 sq. ft. is reserved for
storage space. Another 1,000 sq. ft. is reserved for processing and the remaining
space will be used for office, restroom, and other requirements.
2. Building: Infrastructure required for energy bar preparation is minimal. Therefore a
little cheaper building may be suitable.
3. Equipment & Machineries: The machineries and equipment required are as per the
capacity of the plant and have been mentioned in the below table.
4. Furniture & service lines: Office needs to be well furnished. Services lines like
water pipes, electricity lines, ventilation ducts, lighting and telephone lines, etc were a
major expense.

78
Table 19.1 Fixed investment
Sr. no. Expense for Amount in Rs.
1) Building with land *(not in fix cost)
12,000 per month
Rent
2) Deposit for land and building 30,000
3)
Machineries & Equipment’s with installation
charges
1,73,000
4) Development cost & services 50,000
Total 2,53,000
19.3 Working Capital
Working capital is the cost required to maintain continuous production in industry. The
capital required for production and expenses per month as required is given as follows.
1000 kg per month
Table 19.2Raw material cost
Sr.
No
Material description
Cost per
kg
Material
required per
month (kg)
Total cost (Rs.)
1. Jaggery 50 400 20,000
2. Popped Amaranth seeds 160 50 8,000
3. Oats 90 100 9,000
4. Peanuts 80 100 8,000
5. Flax seeds 160 75 12,000
6. Melon seeds 200 75 15,000

79
7. Chocolate 170 170 28,900
8. Desi Ghee 450 30 13,500
9. Primary Packaging 270 15 4,050
10. Secondary packaging boxes 30 10 300
11. Caustic & Nitric for CIP 50 10 500
Total 1,19,250
Table 19.3 Salary of factory workers
Sr. no. Designation
Monthly salary
per person (Rs.)
No. of
persons
Total
expenses
1) Workers 12,000 4 48,000
2) Technician 18,000 01 18,000
3) Storekeeper 15,000 01 15,000
4) Accountant 15,000 01 15,000
5) Plant supervisor 25,000 01 25,000
Total 1,21,000
Table 19.4 Service charges
Sr. no. Description Rate Consumption
Total per
month (Rs.)
1) Electricity 8.57 Rs/kW 1200 10,284
2) Water 8 Rs/1,000 liter. 25,000 200
3) Generator fuel 68 per liter 5 340
4) Telephone & internet 1000 per month
Unlimited
plan
1,000
Total 11,824

80
Table 19.5 Other contingency expenses
Sr.
no.
Description of expenses Monthly
amount
1) Transportation 15,000
2) Advertising 30,000
3) Events & Meetings 5,000
4) Miscellaneous expense 5,000
5) Documentation & Legal Fees 2,000
Total 57,000
Table 19.6 Total working expenses
Sr. No. Particular Expenses (Rs.)
1) Raw material per month 1,19,250
2)
Rent per month (Land and
building)
12,000
3) Manpower per month 1,21,000
4) Utilities and services per month 11,824
5) Other contingency cost per month 57,000
Total 3,21,074

81
19.4 Break Even Analysis
We are calculating the minimum number of kg’s of product to be sold to get back our
invested fixed cost.
We required 321.124 Rs per kg of productions. Refer table. 19.8
Working capital required for 25 days of a month is calculated in table 17.6. which is
3,21,074 Rs. for 25 days.
Now for working capital required for one day is 12,842.96 Rs.
We produce 2,000 bars per day, which is selled at Rs. 20 per bar. Means, We earn 40,000
Rs per day.
Formula:
B.E.P.in Kg’s = Fixed cost/ (selling revenue per kg– manufacturing cost per kg)
= 2,53,000 / ( 1000 - 321.124)
= 372.6748 kg.
We required to sell 373 kg’s of product to regain fix investment.
B.E.P.in days = Fixed cost/ (selling revenue per day– manufacturing cost per day)
= 2,53 ,000/ ( 40,000 - 12,842.96)
=2, 53,000/ 27,157.04
= 9.316185 days ~ 10 Days
The company will recover this cost after 10 days.

82
19.5 Profit Analysis
Considering the daily production of 40kg (2,000 snack bars) and 25 days of
production per month profit was calculated.
Profit per month:
1. Snack bars produced per month = 50,000 bars
2. Value of produce if we sell it at Rs. 20 per bar= 10,00,000 Rs.
3. Monthly expenses for productions are raw materials, rent, manpower, services and
other expenses = 3,21,074 Rs
(Refer table no: 1.6 – expenses, except fixed one.)
Monthly Profit = ( Monthly sales of product - Monthly Expenses on production)
= 10,00,000 - 3,21,074
= 6,78,926 Rs.
Yearly Profit = 81,47,112 Rs.
Profit (%) = ( Monthly sale of product - Monthly Expenses on production) × 100
Monthly sale of product
= ( 10,00,000 - 3,21,074) × 100/ 10,00,00
= 67.89 %
Table 19.7 Manufacturing cost:

83
Material
Cost Per
kg (Rs.)
Quantity
(g)
Cost per
100g of
bar (Rs.)
Cost per
bar(20g)
(Rs.)
1. Popped Amaranth seeds 160 5 0.8 0.16
2. Oats 90 10 0.9 0.18
3. Peanuts 80 10 0.8 0.16
4. Flax seeds 160 7.5 1.2 0.24
5. Melon seeds 200 7.5 1.5 0.3
6. Jaggery 50 40 2 0.4
7. Chocolate 170 17 2.89 0.58
8. Ghee 450 3 1.35 0.27
9. Packaging materials 270 1.5 0.41 0.08
Total 11.85 2.37
Table 19.8 Production cost for 1 kg
Particular Cost(Rs.)
Ingredients cost 114.4
Packaging & Labeling cost 4.1
Total 118.5
Overhead charges 202.624
Total 321.124
No. of packets in 1 kg 1000

84
Production cost per bar 6.42248
The production cost per Aloha bar = Rs. 6.42248
Selling cost per packet = Rs. 20
Net profit = Selling Price – Production cost
= 20- 6.42248
= Rs.13.57752
Profit in percent = Net Profit × 100
Selling cost
= 13.57752× 100
20
= 67.8876 %

85
CHAPTER 20
MARKETING AND SALES
Marketing involves conducting research support activity and the statistical interpretation
of data into information. This information is then used by manager to plan marketing
activities, gauge the nature of a firm’s marketing environment and attain information
from suppliers.
20.1 Marketing Strategies – 4p’s
 Product
1. Brand Name: Aloha Snack Bar
2. Quality: Basic
3. Packaging: Premium
4. Size of the product: One Size
5. Product USP (Unique selling proportion): None
 Price
Price of the snack bars in the market is high, for example protein bars which are 100-
150Rs, 15-20 gram bars. We are introducing this low cost snack bar at a reasonable price
of Rs 20 only.
1. Cost based method
2. Competition based method
3. Lost leader pricing

86
4. Follow the leader
5. BEP pricing
 Promotion
Promotion is the act of making one’s product visible to a potential customer and in
forming him about its benefits.
A) Paid forms
1. Advertisement (print and electronic media)
i. Pamphlets : None
ii. Banners : None
iii. Hoarding: None
iv. Newspaper: None
v. Magazines: None
vi. T.V: None
vii. Radio: None
Cost involved depending on choices made.
Preparing an attractive advertisement and message or punch line.
2. Sales promotion
i. Good offers: None
ii. Discounts: 10% additional quantity on same price.
iii. Free gifts: None
iv. Free samples: Yes

87
v. Coupons: none
3. Personal selling
Door to door, number of salesperson required, salaries and total cost. (Cost includes
salaries; include transportation charges cost, etc.) For personal selling of product, we
contact person to person we required 4 salespeople.
B) Non- paid forms
1. Publicity
i) Newspaper –none
ii) Radio talks –none
 Place- Distribution network
i) Direct channel (product-consumer )
ii) Single level channel (producer –retailer-consumer)
iii) Two level channels (producer-wholesaler-retailer-consumer)
iv) Three level channels (producer-distributor-wholesaler-retailer-consumer)
v) Any other suitable channel
We used direct channel (producer-consumer) and single level channel (producer-retailer-
consumer) distribution network.
Channel member margin per unit, transportation costs per unit total cost involved
distributor’s terms and policies, return policy adopted, payment terms etc.

88
20.2 Marketing Aspects
 Range of product: -
There is only one product we marketed i.e. Protein and Fiber Rich Snack Bar.
 Marketing of: -Protein and Fiber Rich Snack Bar
In Pune, Hadapsar as well as Loni
 Channel numbers: -wholesalers, retailers, customer
20.3 Market Segmentation of Industry
 Consumer behavior towards the product: - Customers liked the product
 Strength of product:- Crispy texture of the Bar and nutritional value
 Weakness of product :- None
 Where it stands in the competition in the terms of market shares: - It stands against
good competitors in the market due to its good taste and nutritional content.
 Position of the firm among competitors: - good position among competitors.
 Mode of transportation of goods:- transportation was done by commercial vehicle
 Incentive and margins of intermediaries of distribution of product
 Marketing strategies adopted
-Changes in price
-Changes in product quality
-Change in promotion, etc.
Name of close competitors –Patanjali bar and Snickers, Nestle.

89
Promotion natures – promotion of products is important in order to attract the consumer
towards the products.
a) Advertising through media: print/electronic media / demonstration: Promotions are
done by demonstration.
b) Sales of promotion: 10% off on the selling price
c) Personal selling is done by personal contact.
d) Publicity: - person to person.
 Problems faced in marketing of the products:- None
 Total sale of finished product: - 30-40 kg.

90
CHAPTER 21
PRODUCTION DETAIL
Table 21.1: Monthly raw material procurement
Sr. No. Name of Month Ingredients Quantity (kg)
1 February Amaranth 0.30
Oats 0.60
Peanuts 0.60
Flax seeds 0.45
Melon seeds 0.45
Chocolate Syrup 1.02
Jaggery 2.4
Ghee 0.18
Total 6.00
2 March Amaranth 0.10
Oats 0.20
Peanuts 0.20
Flax Seeds 0.15
Melon Seeds 0.15
Chocolate syrup 0.34
Jaggery 0.80
Ghee 0.06
Total 2.00

91
Fig.21.2 Quantity of raw material procured
Table 21.3: Monthly production
Sr.No Name of month Quantity produced
(kg)
1 February 6
2 March 2
Table 21.4: Monthly sales
Sr.No Name of month Quantity sales
(kg)
1 February 6
2 March 2

92
CHAPTER 22
CONSUMER COMPAINTS
for consumer complaints contacts us on
Mob no. 9527504470, 7058746579.
E-mail id- aloha.snackbar4you@gmail.com
 Work more on jaggery’s after taste
 Need an attractive packaging.
 Work on after taste.
 We solved all consumer complaints by improving our ingredient composition and
taking care during handling of product.

93
CHAPTER 23
EFFLUENT WATER TREATMENT
The effluent can be defined as anything that can be affecting our environment by
polluting air, water and soil. The major characteristics of effluent generated are high in
pH, high total dissolved salts, high total soluble sugars, high chemical oxygen demand,
high biological demand, oil and grease. Treating of the effluent generated in the plant
operations is one of the major industrial functions.
23.1 Waste Water Treatment Process
Wastewater is collected in collection pits. Waste water is then transferred to oil and
grease traps, here oil and grease are removed and then this water is transferred to
equalization tanks, pH correction is done here at equalization with the addition of soda
flakes. Water is then transferred to aeration tanks where water is pressurized through root
blowers after aeration water moves to Clarifiers. In Clarifiers, the sludge is separated
from waste water and transferred to final tank with filters in between which clears water
from any flocculation or impurities. This treated water is either disposed of into open
drains or are loaded into tankers which then decant this water into central effluent plants
of the city, sludge is spread on drying beds and is disposed off when it becomes dry.
This treated wastewater can be recycled and used in agriculture, gardening, road
construction, cooling tower, washrooms, etc.
Waste load is determined by a number of different tests, i.e. Biochemical Oxygen
Demand (BOD) is most often used for monitoring wastewater from industries.
The BOD is a biological test used to indicate the amount of oxygen needed to degrade the
organic matter carried by the wastewater.
This test is widely used because:
1) The use of oxygen is often the greatest expense in wastewater treatment, and

94
2) Oxygen deficiency is usually the cause of polluted water and fish kills.
The BOD concentration in a snack bar industry wastewater is usually measured in
milligrams per liter (mg/L) or parts per million (ppm). When the level exceeds 250 to 300
mg/l, many treatment plants apply a surcharge.
The level of BOD in a snack bar processing industry wastewater is directly related to the
type of food product in the wastewater. The waste water also contains cleaning agent,
lubricants and solids removed from equipment and floors.
The BOD concentration can be estimated by measuring fat, protein, and carbohydrates in
wastewater and using the conversion factors. Some discharges contain as much as 12
pounds of BOD per thousand pounds of product produced.
23.2 Chemical Oxygen Demand (COD)
The snack bar industry generates huge amount of wastewater which is treated and then
discharged into municipal drains or central treatment plants. As snack bar plants do not
have heavy metals as its inputs, hence waste water contains only biodegradable waste.
Waste water is generated in the plant are as follows;
Cleaning of factory floor, equipment’s & machineries, hoppers, utensils and trays. This
waste water contains floor dust, sugar, glucose, chemicals which make water highly
acidic in nature.
This effluent water cannot be discharged in open drains as per the standards stipulated by
local/federal govt. different countries have different values for treated water. Following
characteristics are monitored such as pH, BOD, COD, TSS, and TDS, fat, oil & heavy
metals.
Normal treated water value required would be in between these values
 PH= 6-10
 TSS= 1500mg or less
 TDS= 2000mg or less

95
 BOD= 1000mg or less
 COD= 3000mg or less
 OIL & GREASE= 100mg or less
 HEAVY METALS= 1mg or less
To treat waste water in food industry different types effluent treatment methods are used.
Following are the most used methods for wastewater treatment in bakeries.
1) Aerobic – air is mixed with the waste water through blower for aeration depending
upon the volume.
2) Anaerobic – air is avoided, and the water is maintained in closed tank and anaerobic
(bio culture) reaction takes place. Methane gas is generated in such a reaction which
can be used for heating application.
3) A combination of aerobic & anaerobic method – both aerobic and anaerobic tanks are
used for waste water treatment. Waste water is first passed on to anaerobic tanks here
Major BOD reduction is done in aerobic tanks.

96
CHAPTER 24
BY PRODUCT AND ITS UTILIZATION
There is very little waste produced during manufacturing of the Snack bar.
Efficient disposal of waste can be help in:
-Minimizing pollution hazard
-Supply of vital nutrient of our food
-Valuable raw material for gas reactor
-Organic manure
-Extraction of useful byproducts

97
CHAPTER 25
PROBLEMS & DIFICULTIES ENCOUNTERED DURING
HANDS ON TRAINING
1. Failure of equipment i.e. Packaging machine.
2. Improper working of sealing machine.
3. Shortage of laboratory instrument for chemical analysis.
4. The retailers demanded the product at lower price than the MRP.
5. Variability in the quality of raw materials.
6. Variation of quality raw material.
7. Unavailability of utensils and equipment for production.
8. Lack of water supply.
9. More strength is required.

98
CHAPTER 26
CONCLUSION
The hands-on-training programme, designed by the university, has proved to be
beneficial in developing our skills by facing real life situations and solving them. This
programme helped, develop our entrepreneurial skills by processing the products on a
pilot scale and selling them.
During the training programme, we have performed many trails to make the snack bars.
We faced lots of troubles and we got the confidence and technical experience to tackle
such problems.
Trouble shooting during hands on training programme:
 Availability of raw materials in the market
 Availability of potable water for production
 Achievements of good shape and its texture
 Cost variability of raw materials
 Packaging material trader and designing label

99
CHAPTER 27
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