Britannia Industries Limited has been operating since 1892 and is a leading Indian bakery company. It has a 38% market share in India and produces over 400,000 tonnes of biscuits annually. The document provides details about Britannia's Rudrapur production facility, including an overview of the biscuit manufacturing process from receiving ingredients to packaging. Key steps include premixing, creaming, mixing, moulding, cutting, baking, cooling, inspection, stacking and packaging. The facility uses modern machinery and exports biscuits to over 30 international markets.
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Quality control is about inspecting products and trying to take the defective products out. The alternative is a thing called quality assurance. This isn't about inspection, its about putting business processes in place that assure the quality of outputs. Quality control and quality assurance sounds similar but they are quite different.
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2. Company Profile
Britannia Industries Limited(BIL)
*In 1892, with an initial investment of 295 ₹ in Kolkata.
*
*During the tragic World War-II, the Government reposed its trust in
Britannia by contracting it to supply large quantities of "service
biscuits" to the armed forces.
*Leadership position in Indian bakery market with 124 ₹ billion.
*
*Market share of ~38% in the industry.
*
*It has an annual production capacity of 433,000 tonnes and has got
600,000 outlets across India.
*
*In International markets over 30 Countries and a number two brand
in the UAE and Oman.
3. BRIEF ABOUT UTC
*Production trail started on 1st April 2005 in Rudrapur.
*Total plotted area of approximately 20 acres.
*the purpose of production of biscuits as this area is free from all types of
taxes.
*New concept like 5S
*SEIRI: Organization,
*SEITON: Neatness,
*SEISO: Cleanliness,
*SEIKETSO: Standardization,
*SHITSUKE: Discipline
*The Company is perusing for ISO 14001 certificate and it is ISO 22000
certified.
*This unit enjoys the excise and income tax benefit from Uttarakhand
government.
4. PRODUCTS OVERVIEW
• GLUCOSE BISCUITS – BRITANNIA
TIGER
• MARIE BISCUITS – BRITANNIA
MARIEGOLD, NUTRICHOICE
• COOKIES – GOOD DAY BUTTER, GOOD
DAY CASHEW, GOOD DAY PISTA
BADAM
• CRACKERS – 50-50 CHASKA-MASKA
• CREM BISCUITS – TREAT(orange,
pineapple, strawberry, fruit)
BISCUITS
5.
6. MACHINES & AREA
* Boiler
* Hot water generator
* Chocolate melting tank
* Butter melting tank
* Load cell (Butter)
* Lecithin, Solbake, GMS paste preparation
tank
* SMP Solution tank
* Filter for invert syrup
* Invert syrup solution tank
* Sugar syrup solution tank
* Sieves
* Silo
* Flour tank
* Sugar grinder (Manual)
* Automatic sugar grinder tank
*
* Cold store
* Flour sampling sieve
* Cocoa powder
* Weighing balance (Heavy)
* Atta sifter sieve
* Bran sifter sieve
* Lift for uplifting materials.
* Chocochip store
* Butter, HVO store area.
* Cold store for nuts.
* Cold store for flavor
* Sugar storage area.
* Flour storage area.
* Laboratory
* General store office
* Wash room.
* Shelf life room
*
*
8. Wheat Flour
*Principal ingredient in Bakery products.
*Unique ability to form Gluten.
*Gluten is made of Gliadin & Glutenin (Insoluble Proteins).
*Soluble proteins present in wheat flour are Albumin & Globulin.
*Gluten is elastic–like and forms matrix.
*Gluten forms only on mixing with water.
*Gliadin contributes to elasticity & Glutenin imparts strength
(Resistance).
*Both quantity & Quality of gluten are important in assessing
the strength of flour.
9. WATER
*2nd major ingredient in Bakery products.
*Hydration of proteins.
*Acts as a dispersion medium for sugar & other chemicals.
*The consistency of dough largely depends on water.
*An excellent leavening agent.
*Medium hard water is preferred for most of the Bakery
products, as some of the mineral salts (like Calcium salts)
have a strengthening effect on gluten and some (like
Ammonium salts) serve as yeast foods.
10. FATS & OILS
*
*Act as lubricants.
*Tenderizing agent.
*Provides texture/structure to the product.
*Act as aerating agents.
*Eating quality (Palatability).
*Moisture-barrier in finished products.
*
13. MILK & MILK PRODUCTS
*Flavor and taste contribution.
*To enhance crust color and bloom.
*To improve tenderness of the product.
*To improve the texture without altering the symmetry and
crumb color.
*To reduce the greasy feeling in sandwich creams.
*As an alternate to eggs (use of whey protein concentrates).
*
14. FLAVOURS
*Taste enhancer
*Dispersibilty in water or fat as per requirement
*Expression/Stability at the product pH.
*Compatibility to the product as the expression of flavor
generally varies with the fat content in the product.
*Masking any undesirable odour from the product.
*Closeness to the natural product envisaged.
*
15. COLOURS
*To provide identity to the food product.
*To provide variety to the consumer.
*To correct the natural variations in the color of the food.
*To enhance the natural color but at levels lower than that
usually attached to the given food.
*To protect food products, flavors and vitamins that can be
affected by exposure to light.
*
17. LEAVNING AGENT
*
*Rise the volume of dough
*Baking powder contains baking soda and the right amount of
acid to react with it.
*Batters made with double acting baking powder rise twice;
*once when dry and moist ingredients are mixed together, and
again when the product is baked.
*
1-S.B.C.(Sodium bicarbonate)
2-A.B.C.(Ammonium bicarbonate)
18. Above 70 °C, it gradually decomposes into sodium carbonate,
water and carbon dioxide. The conversion is fast at 250 °C
2NaHCO3 → Na2CO3 + H2O + CO2
Leavening agents where in application low final moisture
content is reached in baked products such as cookies and
crackers.
NH4HCO3 → NH3 + H2O + CO2
1-S.B.C.(Sodium bicarbonate)
2-A.B.C.(Ammonium bicarbonate)
19. 1) Wheat flour 2) Palm oil:
• % Moisture: 14 (max.)
• % Total ash: 0.8 (max.)
• % Acid insoluble ash: 0.05 (max.)
• % Alcoholic acidity: 0.12 (max.)
• % Gluten on dry basis: 7.5 (min.)
• Germ oil acidity (as oleic): 15 (max.)
• Granularity : 85 mesh sieve ( 99%
should pass through )
• Sedimentation value : 17 to 30
• Taste and colour : should be
characteristic
• Extraneous matter : should be absent
• Origin : should be of vegetable origin
*% FFA -0.10 max. (as oleic acid )
*% Moisture: 0.10 (max.)
*Peroxide value: 1.5 (max.)
*Refractive index : 1.4491- 1.4552
*Saponification value : 195 – 205
*Unsaponifiablematter: 1.2 %( max.)
*Iodine value : 45 – 56
*Melting point: 37ο C (max.)
*
3) Sugar:
*% Moisture : 0.1
*% Total sugar : 99.5
*SO2 : 70.0ppm
*
ACCEPTANCE CRITERIA FOR INGREDIENTS
28. LECITHIN PASTE PREPARATION
1 Kg
Lecithin +
3 Kg HVO
Mixture dumped
to Lecithin Paste
Preparation
Tank
Steam from
boiler
Mixture melts
and ready to
be used
31. Then it is mixed
with other
ingredients for
further 2 minutes. SIGMA ARM MIXTURE
• To entrap air and to mix
all ingredients.
• It involves mixing of fat,
sugar, flavour
except flour,
creamed for 8-12
minutes.
CREAMIN
G
35. Benefits of Continuous Mixing
*Simplifies the mixing process
*Disperses ingredients consistently
*Simplifies dough feed equipment
*Provides tight control over the mixing process
*Is safer , more sanitary and can be operated with less labour
and energy than batch mixing
*Is easy to sanitize, maintain, clean and inspect due to the
clamshell design
*No dough contamination because the dough is never exposed
to the environment
*Is easy to operate due to the user friendly controls
*Controls ingredient metering to the mixer so it’s precise and
uninterrupted.
39. BAKING
The zones are classified as:
There are 7 independent zones in all three plants. These
are
a) Proofing zone: zone 1 & 2 (Structure is set here)
b) Puffing zone: zone 3 & 4 (Product get oven spring)
c) Baking zone: zone 5 & 6 (Moisture removal of product)
d) Colouring zone: zone 6 & 7 (Millard & Caramlization)
40. The Physical changes
The Chemical changes
• Large reduction in product
density.
• Development of an open
porous or flaky structure.
• Change of shape associated
with shrinkage or spread
and increase in thickness.
• Reduction in moisture level,
to between 1-4%.
• Change in surface
coloration (reflectance).
•
*1. Gas formation
*2. Starch gelatinization
*3. Protein denaturation
*4. Caramelization of sugar
*5. Dextrinisation of starch
*
41.
42.
43.
44.
45.
46. *COOLING
These baked biscuits are then
passed on to cooling conveyors
for natural cooling prior to
packaging. The temperatures
are brought down to room
temperatures. It should
between 35°- 40°C.
49. PACKAGING
30 to 150 Packing per minute.
Auto feeder Ferrari Machines.
These packs are then put into
secondary packaging like cartons to be
transported to retailers.
Packing machine can be selected as
per the plant capacities and nature of
packing.
53. Batch no.
For Good Day (CHOCO-CHIP)
BISCUITS NET WEIGHT 75g
MRP. ₹ 20.00
(incl. of all taxes)
PKD. 30/07/15
LOT No. B071595
MACHINE CODE: 03C01
*
*BEST BEFORE SIX MONTH FROM PACKAGING
55. ELECTRICITY SUPPLY
*The transformer then converts the 11 KVA supply to 33 KV.
*
*
*Volt remains almost constant to 33 KV but ampere fluctuates
with variation in power consumption during production and
other factors. It is generally of 25K amp.
*
*
*There are 4 sets of A.C Diesel generators assemble for
emergency purpose. Three is of 625 KVA and one is of 500
KVA.
61. Fuel
CNG, Thermofluid oil fuel used by Britannia industries limited.
Export
BIL Rudrapur export 60 tonnes of biscuits per month to
Singapore, USA, Kuwait, Ghana, Oman, Saudi Arabia, Bahrain,
Seychelles etc.
We work with UTC team
*Officers, SGR & Manager 99
*Total Manpower (Workers) 2200
