PEPSICO INDUSTRIAL TRAINING
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This document summarizes projects conducted at a snack food company with 3 plants in India. It describes the company's production lines and key achievements in quality and sustainability. It then summarizes 3 projects: 1) analyzing seasoning variability, 2) addressing underweight issues in packaged chips, and 3) improving quality of a rice and corn snack called Kurkure. For project 3, new analysis techniques were developed to better understand the intrinsic properties of ingredients and their impact on extrusion properties, as existing techniques had limitations.
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![COMPANY PROFILE
3 SNACK FOOD PLANTS-
CHANNO,PUNE,DHULAGARH
75 CRORES INVESTMENT FOR
ESTABLISHMENT OF DHULAGARH
PLANT IN SANKRAIL.
2 PC LINE-PC 24 AND PC 66.
2 KKR LINE-KKR1,KKR2
1 BCP LINE.
FRITO COMPANY
AND H.W.LAY &
COMPANY[1930]
FRITOLAY
PEPSI
COLA](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)
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PEPSICO INDUSTRIAL TRAINING
- 2. COMPANY PROFILE 3 SNACK FOOD PLANTS- CHANNO,PUNE,DHULAGARH 75 CRORES INVESTMENT FOR ESTABLISHMENT OF DHULAGARH PLANT IN SANKRAIL. 2 PC LINE-PC 24 AND PC 66. 2 KKR LINE-KKR1,KKR2 1 BCP LINE. FRITO COMPANY AND H.W.LAY & COMPANY[1930] FRITOLAY PEPSI COLA
- 3. KEY ACHIEVEMENTS RANKS 4th IN PEPSICO INTERNATIONALS AND 1st IN INDIA FOR AIB AUDIT USAGE OF RICE HUSK BOILER AS FUEL FOR TOTAL PRODUCTION MANAGEMENT, PRINCIPLES OF KOBETSU KAIZEN AND JISHU HOZEN ARE FOLLOWED WORKS ON ISO NORMS AND FOLLOWS HACCP ANALYSIS ZERO EMISSION PLANT
- 6. PROJECT 1-ANALYSIS OF SEASONING CAPABILITY IMPORTANT TERMS Cp GREEN BAND RED BAND Cpk
- 7. PROJECT 1-PROCEDURE OF DETECTION 3ml potassium chromate 125 ml distilled water 2 gm grinded sample chips TITRATED AGAINST N/10 SILVER NITRATE
- 8. PROJECT 1-OBSERVATION TABLE AND CALCULATION
- 10. PROJECT 2-UNDERWEIGHT ISSUES IN PACKAGED POTATO CHIPS BOOSTER HOPPER WEIGH HOPPER POOL HOPPER BAG MAKER
- 11. PROJECT 2- FACTORS AFFECTING UNDERWEIGHT 1. FORMER CHOKING DUE TO OVERSIZED POTATOES 2. FORMER FINGERS TOO CLOSE 1.HIGH NITROGEN INFUSION FLOW RATE
- 12. PROJECT 2-FACTORS AFFECTING UNDERWEIGHT 1.FLOOR VIBRATIONS DUE TO TRANSFORMERS 2.DUMP DELAY. 1.STICKINESS OF CHIPS 2.CHIPS ON THE EDGE OF WEIGHING HOPPER
- 13. PROJECT 2- TROUBLESHOOT • CONTINUOUS INSPECTION OF N2 INFUSION FLOWRATE •SPANNING OF EQUIPMENTS • WIGHING HOPPERS SHOULD BE AWAY FRON ANY AIR CONDITION TO PREVENT AIRFLOW • CIP AFTER EVERY NEW FLAVOUR PRODUTION HOPPER OF THE MACHINES WERE REPLACED INCREASED DUMP DELAY ANTIFLOOR VIBRATION MECHANISM AUTOZERO MECHANISM OF THE WEIGHING HOPPERS
- 14. PROJECT 2- COMPARITIVE GRAPHICAL ANALYSIS BEFORE TROUBLESHOOT AFTER TROUBLESHOOT
- 15. PROJECT 3- QUALITY IMPROVEMENT OF KURKURE • MOISTURE CONTENT>17% • DAMAGED AUGER • INCORRECT GAP BETWEEN STATOR AND CUTTER RING OF EXTRUDER • MOISTURE CONTENT>16% • WRONG RATIO OF RICE:CORN:GRAM • MOISTURE <16% • AUGER SPEED>148 RPM CLUBS/ROUGH AND SKINNY NUBS BITS AND PIECES CROWN FEET
- 16. PROJECT 3 - OLD ANALYSIS TECHNIQUES PERFORMED ON KURKURE MOISTURE VARIATION MEAL COMBINATION MEASUREMENT OF VISCOSITY OF MEAL BY RVA TECHNIQUE EXTRUDER RPM CHECKING INCOMING MEAL QUALITY
- 17. PROJECT 3 – DRAWBACKS AND THEREBY ORIGIN OF NEW IDEA INCREASING CONSUMER COMPLIANCE RVA FAILS TO DETECT PROPER COMBINATIO N OF MEAL VARIATION OF RPM IMPACT ON TEXTURE 1. Thought arises with the principle of relation of intrinsic property of meal . 2.Relation between starch and its constituents and their impact on extrusion ? ? ? ? ?
- 18. PROJECT 3 – OBSERVATION TABLE
- 19. PROJECT 3 – ANALYZING INTRINSIC PROPERTY OF THE MEAL ESTIMATION OF AMYLOSE AND AMYLOPECTIN IN MEAL DETERMINATION OF REDUCING SUGAR IN MEAL
- 20. ACKNOWLEDGEMENT THROUGH MY ENTIRE TRAINING PROGRAM,I CAME TO LEARN ABOUT SEVERAL QUALITATIVE TESTS.BESIDES VAST EXPERIENCE IN PRODUCTION AND PACKAGING OF POTATO CHIPS AND EXTRUDED PRODUCTS. I WAS FORTUNATE ENOUGH TO ATTEND A 1 DAY TRAINING PROGRAMME HEADED BY THE ENGINEERS OF ISHIDA FROM GERMANY. CAME IN AQUAINTANCES WITH SEVERAL STATISTICAL QUALITY CONTROL TOOLS AND LEARNED MANY TPM TECHNIQUES. GOT OPPORTUNITY TO WORK WITH PEPSICO TEAM AND LEARNED PEOPLE MANAGEMENT.
- 21. THANK YOU