1. A INDUSTRIAL TRAINING PRESENTATION
MANUFACTURING OF BISCUITS
BRITANNIA INDUSRTIES
Submitted for partial fulfillment of award of
B.TECH.
Degree in
FOOD ENGINEERING & TECHNOLOGY
By
KASHISH KATIYAR (201401140014)
Department of Food Technology
Institute of Engineering and Technology
Bundelkhand University, Jhansi(U.P)
2. CONTENT
• Introduction
• Types of biscuits
• Raw material
• Role of ingredient
• Manufacturing process of good day butter biscuit
• Packaging process
• Manufacturing process of bourbon biscuit
3. BRITANNIA INDUSTRIES LIMITED (BIL)
• In 1892, with an initial investment of 295 rupees in Kolkata.
• During the tragic world war 2, the government respond 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 rupee.
• Market share of 38% in the industry.
• Britannia is 100 year organization with the presence in biscuit, bread, cake, rusk,
dairy, and snacks.
4. BRIEF ABOUT BRITANNIA UTTARANCHAL (UTC)
• Production trial 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 type of taxes.
• There are four plants in the unit and each plant is used for different variety of
Biscuits as follows.
5. TYPES OF BISCUIT
LINE TYPES OF BISCUIT
LINE-1 (Nutri choice digestive, Nutri
choice oats, Nutri choice
digestive zero, Nice time)
LINE-2 - Good Day (Butter, Cashew,
Almond & pista)
LINE-3 - (50-50 Maska-Chaska, Tiger
crunch, Good day Choco
chip)
LINE-4 Treat (strawberry, orange,
pineapple, Kool vanilla,
Funky Choco, bourbon)
7. ROLE OF INGREDIENTS
• WHEAT FLOUR :-
• Principle ingredient in Bakery products.
• Unique ability to form gluten.
• Gluten is made of gliadin & glutenin (insoluble protein).
• Soluble proteins present in wheat flour are albumin and globulin.
• Gluten is elastic in nature.
• Gluten forms only on mixing with water.
• Gliadin contributes to elasticity & glutenin imparts strength.
• Both quantity and quality of gluten are important in assessing the strength of flour.
8. WATER
• Second major ingredient in bakery products.
• Hydration of protein.
• Act as a dispersion medium for sugar and other chemicals.
• The consistency of dough largely depend on water.
• An excellent leavening agent.
• Medium hard water is preferred for most of the bakery products.
• Affects storage life of raw as well as finished product.
• Moisture content in final form of biscuit is just 2-3% which is not enough for microbial growth.
9. FATS & OILS
• Act as lubricants.
• Tenderising agent.
• Provide texture / structure to the product.
• Act as aerating agents.
• Eating quality (palatability).
• Moisture barrier in finished products.
10. SUGAR
• Sugar and syrup are one of the major ingredients of most biscuit. It provides
sweetness to the biscuits.
• On caramelization during baking, it imparts a peptizing crust color and improves the
appearance of biscuits.
• It improves the flavor of the product, makes biscuit hard. It controls the spreading of
biscuits.
• Help in creaming with fat.
• Sugar contributes the nutritional value of biscuits, and it is a quick source of energy.
• It also act as a preservative.
11. SALT
• Act as Preservative.
• It gives a little bit of salty taste to biscuit.
• It is used mainly for its flavor & flavor enhancing properties.
• It brings out the taste of other ingredients particularly sugar and helps to improve the flavor of
the product.
• Flavour enhancer
• Fermentation control
12. MILK & MILK PRODUCT
• Flavour and taste contribution
• To enhance crust colour and bloom.
• To improve tenderness of the product.
• To improve the texture without altering the symmetry and crumb colour.
• To reduce the greasy feeling in sandwich creams.
• As an alternate to eggs (use of whey protein concentrates).
13. FLAVOUR
• Taste enhancer
• Dispersibility in water or fat as per requirement.
• Expression / stability at the product ph.
• Compatibility to the product as the expression of flavour generally varies with the
fat content in the product.
• Closeness to the natural product.
14. COLOURS
• To provide identity to the food product
• To provide variety to the consumer.
• To correct the natural variation in the colour of food.
• To enhance the natural colour but at level lower than that usually attached to the
given food.
15. EMULSIFIERS
• Emulsifier forms a large group of compounds whose function is to stabilize
mixtures of two immiscible liquids.
• Help in uniform spreading of fat over hydrophilic ingredients such as flour, sugar,
etc, in the dough.
• Helps in reduction of fat.
16. LEAVNING AGENTS
• Rise the volume of dough.
• Baking powder contains baking soda and the right amount of acid to react with it.
• Batter made with double acting baking powder rise twice.
• Once when dry and moist ingredients are mixed together and again when the
product is baked.
• Sodium bicarbonate & Ammonium bicarbonate are most commonly used.
20. INGREDIENT USE FOR GDB
Ingredient Amount in kg
SODA 0.9KG
AMMONIA 1.3KG
SALT 2.8KG
SUGAR 90KG
BUTTER 13.2KG
LECITHIN 2.6KG
P.OIL 118KG
INVERT SYRUP 18KG
WATER 33L
MILK 7.2KG
22. CREAMING
• The function of creaming is to entrap air and to mix all ingredients.
• It involves mixing of fat, sugar, and other ingredients such as;
• Flavour salt
• Soda Invert syrup
• Ammonia Water
• Butter Milk
• M sugar Palm oil
• Lecithin
• Creamed for 8 to 12 minutes.
• For good day butter creaming time is 3.50 minutes.
23. MIXING
• Process of mixing of cream and flour
for 2 minutes.
• After mixing dough is formed and
transferred to the forming area.
• For good day butter mixing 2 min
fast.
• For slow mixing 25-30 rpm.
• For fast mixing 50-55 rpm.
24. MOULDING
• Dough passes through
several rolls and from sheet
and then converted in to
one uniform sheet of
desired thickness.
• Moulder or cutter are used
to cut sheet or convert
dough in to desired shape
or size.
25. BAKING
• There are 7 independent zones in all
three plant, these are :-
• Proofing zone: zone 1 & 2 (structure is
set here )
• Puffing zone: zone 3 & 4 (product get
oven spring & ammonia release)
• Baking zone: zone 5 & 6 (moisture
removal of product)
• Colouring zone: zone 6 & 7 (maillard
and caramelization
• Baking time for good day butter 6.44 min.
26. Baking zone Temp °C
Zone 1 222-220 °C
Zone 2 291-290 °C
Zone 3 337-335 °C
Zone 4 345-340 °C
Zone 5 323-330 °C
Zone 6 263-285 °C
Zone 7 241 °C
27. COOLING
• Cooling is mainly done with the
help of belt conveyor.
• This process is done for about 7-
10 minute.
• There should be adequate
number of high-speed fans
blowing on the cooling
conveyors to cool the biscuits.
28. PACKAGING
• These biscuits are then stacked and fed
into packing machine for packing.
• The role of this machine is to do
primary packaging of biscuit stacks
• It consists of former box.
• Propelling roller, roller 1, roller 2.
• Upper jaw1, upper jaw 2, lower jaw 1
and lower jaw 2.
• These packets are then put into
secondary packaging like cartons to be
transported to retailers.
30. INGREDIENT USE IN BOURBONE AMOUNT IN KG
REFINED WHEAT FLOUR 239KG
AMMONIA 3.6KG
SALT 0.5KG
SODA 1.6KG
SUGAR 91KG
PALM OIL 76.2KG
WATER 32L
STARCH 15 KG
BAKING POWDER 5KG
COCOA POWDER 5KG
BLACK JACK 18KG
GMS 5.7KG
FLAVOUR 0.2 KG
CARAMEL 1.2KG
COLOR 0.4KG
31. • Creaming time for bourbon is 10 min.
• Mixing 4 min fast and 2 min slow.
• Moulding
• Baking : There are 6 zones for baking.
• Baking time for bourbon biscuit is 7.1 minute.
Zone 1 188-180 °C
Zone 2 267-270 °C
Zone 3 280-280 °C
Zone 4 187-180 °C
Zone 5 192-180 °C
Zone 6 139 °C
