The document outlines the manufacturing process for making biscuits at Parle. Key steps include: mixing raw materials, moulding dough, baking in a 260 foot long oven, cooling on a 260 foot long conveyor, packaging, and dispatching finished biscuits. Parle aims to minimize wastage at each step and ensures quality through processes like HACCP and regular staff training. The production capacity has increased from 160 tons in 1960 to 35,000 tons currently.

1. Manufacturing Process

2. Process

3. MIXER
LAMINATOR
GAUGE
ROLLS
PACKAGING
MACHINE
MOULDER
STACKER
OVEN
COOLING
PROCESS FOR MAKING
BISCUITS

5. What Parle does differently??
Raw Materials
260 feet
long
Cooling
Conveyor
Stephen Mixer
RAW
MATERIAL
TESTING
Cooling
Mixing
Rotary Moulder
260 feet long
oven
Baking
Moulding

6. Difference
Counting
unit
Stalking
Table
Auto
Feeding
Machine
Multi Pack
Wrapping
PolyBag
Sealing
Machine
Corrugat
e Box
Section
Dispatch
Section

7. Flow Chart

8. Production Capacity
1960
• 160
Tones
2000
• 22000
Tones
2012
• 35000
Tones

9. Wastage
17%
20%
OPERATOR
AWAY
MACHINE
PROBLEM
3%
Another cause of wastage is
machinery breakdown. So
regular checks on the machines
must be adopted.
DELAY IN
MATERIAL
POWER CUT
60%
120
100
80
60
40
20
0
5S has reduced wastage wastage inc.Jagruti group HACCP has improved quality
QC reduced 5S has improves knoweldge Group activities has improved the efficiency
OPL eff.
Small
has improved quality

10. Wastage
1% wastage comes from Production Capacity
Used for
Cattle
Feeding
Broken
Pieces
Are sold
for
rs.33/kg
The under baked or over baked biscuits are
reprocessed by sending them back to the
chura store and thus minimizing the wastage.

11. PARLE PRODUCTS – ‘AN
EPITOME OF QUALITY’
The wastage in the
plant is least and the
production team and
the workers try their
level best to reduce it
even more.
The wastage of the
biscuits that fall on the
floor is minimized by the
use of trays under the
machines
Also a PQS test was
taken of workers and
their average score was
75.86%

12. Quality
“QUALITY, HEALTH AND GREAT TASTE”
“Best product with long lasting freshness”
“Every batch of biscuits and confectionery
are thoroughly checked by the expert staff,
using the most modern equipments hence
ensuring the same perfect quality across the
nation and abroad “
“HACCP and quality management system
which together form an organization's Total
Quality Management”
Hygiene is the precursor of
every process at Parle.