Project I did on Value Stream Mapping in Cadbury

1. Process and Waste Mapping of Gum Plant
&
Process Mapping and Texture Analysis of Soft
Chew
Submitted by:
Sahil Garg(1050138)
Akchitta Srivastava
(1050102)
Project Manager:
Mrs. Horsuwan
Papasaratorn (TDS &
CSMS Manager)

3. Objective:
To understand the complete process of gum
manufacturing.
To understand the Key Process Indicators, Zero base, Bill
of Materials.
To provide the fact base.
To find out the opportunities to reduce salvage and waste.
To link the financial base with the actual plant data.

4. Gum process and Manufacturing

The gum plant is divided in two areas:
1.
SEA Plant
2.
Japan Plant

Each plant has four divisions:
1.
Manufacturing Process
2.
Aging room
3.
Coating and Polishing
4.
Packaging

5. PROCESS DESCRIPTION

6. Continued..

7. VALUE STREAM MAPPING(VSM)
VSM is a visualization tool oriented to the Toyota
version of lean manufacturing.
It helps to understand and streamline work processes.
The goal of VSM is to identify, demonstrate and
decrease waste in the process.
VSM is primarily a communication tool but also used
as a strategic planning tool and a change management
tool.

8. Objectives:
To understand Cycle Time, Change Overtime,
WIP, %Waste and % Salvage in each step of CFP
process .
To identify Non value added activities in the
process.
To make the process as close to lean as possible.
To reduce the lead time of the product.
To identify opportunities for future improvement.

9. What Is Value?
A capability provided to a customer,
 of the highest quality,
 at the right time,
 at an appropriate price,
as defined by the customer.
•"Value" is what the customer is buying
•Always think first about the end-customer
Who
is the customer?
What are they buying?
•Describe value using the customers' words

10. What Is Value Stream Analysis?
Planning tool to optimize results of
eliminating waste
future state VSM
current state VSM
+
+
Lean
Basics
=

11. Apply Five Simple Principles:
 Specify value from the standpoint of end customer
 Identify the value stream for each product family
 Make the product flow
 So the customer can pull
VALUE
Perfection
VALUE
STREAM
 As you manage toward perfection
PULL
FLOW

12. What is the Value that Flows?
Specify value from the standpoint of the end customer
Ask how your current products and processes disappoint your
customer’s value expectation:
 price?
 quality?
 reliable delivery?
 rapid response to changing needs?

13. 7 Forms of Waste
PEOPLE
Motion
Processing
LI T
QUA
Fixing
Defects
TYPES
OF
WASTE
Waiting
Inventory
Y
Moving Making Too
Things
Much
T
NTI
A
QU
Y

14. CURRENT STATE I

15. CURRENT STATE II

16. Analysis:
Current CFP process has only 23% Value added out of
the total lead time of 11.6 days.
5.5 Days Inventory in process (WIP ) is a major of Non
Value Added .
 Total Changing over time in CFP process is 21 hr which
speedy project plan to reduce CO time down .
Bottling OEE is very low around 58% .
High waste at coating and sorting area = 4.3% .
Cycle time 11 hr for 2 Ton at packing part (5 Mc) .

17. Opportunities
Reduce WIP 5.5 Days which are before coating and
after sorting.
 Reduce CO time as per Speedy Target.
Improve Bottling OEE from 58% to 75%.
High waste at coating and sorting area = 4.3%.
Removal of sorting step from the process.

18. FUTURE STATE I

19. FUTURE STATE II

20. Mapping of CFP
Salvage
Gum Base
Liquid Center fill
Syrup &
Center
Materials
I
Melter
Aug08
Mixer
Extruding
Total In-Out -Mixer,Forming
Recorded waste
Recorded Salvage
Inventory
Actual Waste %
All Matrials (Center Bulk)
Standard Waste %
All Matrials (to Center Bulk)
Forming
2.5%
0.4%
0.9%
1.2%
Total In-Out -Mixer,Forming
Recorded waste
Recorded Salvage
Inventory
Actual Waste %
All Matrials (Center Bulk)
Standard Waste %
All Matrials (to Center Bulk)
Actual Financial %(Zero base) All Matrials
Total In-Out -Coating
Recorded Dust +waste
Recorded Salvage
Missing/Unrecorded
-
Center Bulk
3.0%
Center bulk
All Materials
Center Bulk
Actual Financial %(Zero base) All Matrials
Sep08
I
Aging
2.7%
0.5%
0.4%
1.8%
Total In-Out -Coating
Recorded Dust +waste
Recorded Salvage
Missing/Unrecorded
-
Center Bulk
3.0%
Center bulk
All Materials
Center Bulk
Coating
Sorting
packaging
4.6%
Total In-Out -Sorting
2.1%
2.3%
Recorded waste 1.8%
Inventory/Miss
0.2%
2.3%
Overall Loss(Input-good Output)
8.1%
0.5%
Coated Bulk
2.1%
2.5%
Coated Bulk
4.0%
2.5%
Coated Bulk
0.5%
4.5%
Total In-Out -Sorting
1.4%
2.6%
Recorded waste 1.0%
Inventory/Miss
0.4%
1.9%
Overall Loss(Input-good Output)
7.7%
0.5%
Coated Bulk
2.8%
2.5%
Coated Bulk
4.0%
2.2%
Coated Bulk
2.8%

21. Aug'08
2.5
%age
2
1.5
1
0.5
0
MIXER
FORMING
AGING
COATING
SORTING
COATING
SORTING
Proces s
salvage
Miss
w aste
Sep'08
3
%age
2.5
2
1.5
1
0.5
0
MIXER
FORMING
AGING
Process
salvage
Miss
w aste

22. Missing data at the sections is most probably the
inventories or unrecorded waste.
Coating defect to be corrected by improving coating
process.
Overall loss is around 8% per month, in comparison to the
monthly record of around 4%.
Dust waste is not included in Waste in OEE.
Financial and plant data do not match.

23. Mapping of XP
Salvage
Gum Base
Syrup &
Center
Materials
I
Melter
Aug08
Mixer
Extruding
Total In-Out -Mixer,R&S
Recorded waste
Recorded Salvage
Missing
Actual Waste %
All Matrials (Center Bulk)
Standard Waste %
Actual Financial%
(Zero base)
R&S
0.0%
0.5%
1.5%
-
I
Aging
Coating
Total In-Out -Coating
Recorded Dust +waste
Recorded Salvage
Missing
packaging
Sorting
2.6%
Total In-Out -Sorting
2.9%
2.1%
Recorded waste 0.1%
0.5%
Recorded Salvage 2.8%
Inventory
Overall Loss(Input-good Output)
7.5%
0.5%
Coated Bulk
Center Bulk
All Matrials (to Center Bulk)
1.8%
3.8%
Coated Bulk
3.5%
All Matrials
0.5%
Center bulk
All Materials
Center Bulk
-2.6%
Coated Bulk
7.0%
Total In-Out -Mixer,R&S
Recorded waste
9.9%
2.3%
Total In-Out -Coating
Recorded Dust +waste
2.1%
1.9%
Total In-Out -Sorting
5.6%
Recorded waste 0.10%
Recorded Salvage
Sep08
-
4.1%
Recorded Salvage
0.0%
Recorded Salvage 1.8%
3.5%
Missing
Missing
Actual Waste %
All Matrials (Center Bulk)
Standard Waste %
Actual Financial%
(Zero base)
-
Center Bulk
All Matrials (to Center Bulk)
1.8%
All Matrials
1.5%
Center bulk
All Materials
Center Bulk
0.2%
Inventory
Overall Loss(Input-good Output)
2.3%
4.0%
3.8%
12.5%
Coated Bulk
3.8%
3.8%
Coated Bulk
3.5%
6.8%
Coated Bulk
5.1%

24. Comparison of Recorded Data
Data Split(Sep'08)
4.5%
4.1%
4.0%
3.5%
3.5%
3.0%
2.3%
2.5%
1.9%
2.0%
1.8%
1.5%
1.0%
0.5%
0.0%
extruder
0.4%
0.2%
0.0%
0.1%
coating
Salvage
sorting
Was te
Mis s Data
Data Split(Aug'08)
4.0%
2.8%
3.0%
2.0%
1.0%
2.0%
1.5%
0.5%
0.5%
0.0%
0.1%
0.0%
-1.0%
extruder
coating
sorting
-2.0%
-3.0%
-2.4%
Salvage
Waste
Miss Data
0.0%

25. L iliy -Mapping Was te
12
10
9.9
7.4
8
A ug-08
6
S ep-08
4.10
4
2.60
2.90
3.3
2.1
2
0
ex truder
-0.40
-2
c oating
s orting
pac kaging

26. Summary –Lily
Missing Data (inventory) at Mixer and sorting.
Coating defect reduction.
Give away reduction is very important.*
Weight tolerance 1.53 vs. BOM 1.5 gm.
Overall loss increased to 12% from 7.5% in Sep.
month. This was due to metal detection and hair
contamination.
Dust waste(1.9%) is not included in Waste in OEE .

27. Sep-08
170.0
168.0
Series1
166.0
Series2
Series3
162.0
160.0
Series4
158.0
Series5
156.0
Series6
154.0
Series7
152.0
148.0
Series9
7.
0
10
.0
13
.0
16
.0
19
.0
22
.0
25
.0
28
.0
31
.0
34
.0
37
.0
40
.0
43
.0
46
.0
49
.0
Series8
4.
0
150.0
1.
0
Net Wt./Bottle
164.0
Overall Avg
Min
Max
Giveaway%
Range
155.7
149.9
168.4
3.8%
0 - 12.3%
Series1
0

28. Continued..
Bottling Oct-08
160.0
Series1
159.0
Series2
158.0
Series3
Wt(g)/Bottle
157.0
Series4
156.0
Series5
155.0
Series6
154.0
Series7
153.0
Series8
Series9
152.0
Series10
151.0
Series11
150.0
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15 16 17 18 19 20
Sample No
Overall Avg
Min
Max
Giveaway%
Range
154.6
150.1
159.6
3.1%
0 - 6.4%

30. Background
% Loss (Zero base)
% Give away from bottling JP line(Jun-Oct 2008)
4.5%
4.0%
3.5%
3.0%
2.5%
2.0%
1.5%
1.0%
0.5%
0.0%
Start Papa Project
Start Earth Project
3.6%
3.9%
3.9%
3.7%
3.7%
3.1%
3.3%
3.2%
September
October
YTD
3.0%
3.1%
June
July
3.4%
August
Month
XP
CFT

31. Action Plan for Improvement
Implemented
Plan
1.Study relation of speed M/C with %give
away and find potential point for reduce
2.Action:i Set one page standard
for cleaning and calibration in
shift production
3.Action:ii Set operation procedure for
change cylinder.
4.Action:iii Reduce the vibration of filler
and change design of bush
5.Action:iv Reduce the variation of
checker weight
6.Action:v Study other option for
to reduce with Eng. team
7.Action:vi Pre-proposal for management
team for approve trial
July
W
1 2 3 4
August
September
W
1 2 3 4
W
1 2 3 4
October
W
1 2 3 4

32. Result of study relation speed & %give
away
F ille r s iz e N o .4 7 .5
S p e e d 6 0 b o t t le / m in .
T a rg e t
SL
SU
130 g
130 g
136 g
Histogram
30
20
10
0
Frequency
Frequency
12
9
13
0
13
1
13
2
13
3
13
4
13
5
13
6
M
or
e
B)
M o re
X bar
C pk
1 3 1 .8 5 g
0 .4 1
Fr
equency
129
0
130
12
131
22
132
24
133
22
134
4
135
12
136
3
1

33. Result of study relation speed & %give
away
Fille r s iz e No .47.5
Sp e e d 70 b o t t le / m in.
Ta rge t
SL
SU
130 g
130 g
136 g
30
20
10
0
13
6
M
or
e
13
5
13
4
13
3
13
2
13
1
Frequency
13
0
12
9
Frequency
Histogram
Mo re
Fre que nc y
129
2
130
7
131
20
132
26
133
14
134
12
135
8
136
7
4
X bar
132.19 g
Cp k
0.39
The result show the speed is not significant related with Cpk in speed 60-70 bottle/min

34. Set operation procedure for change cylinder
:Standard for calibration filler before start up line,
during production and change lot pallets gums
:We found the size of cylinder was relate with
volume and weight of pallet in 1st step filling
:We must control the
1st filling about 148g
by change cylinder
size after change
pallets gum new lot
or during production
:Found XP mostly
use size 52-52.5 g
CFT use 47.5-49 g

35. Reduce the vibration of filler and change design of bush in
1st filling
Pallets drop into
cylinder
ove
M
u
in /o
t
Some pallets to slip off
from here during production
:Change a new bush for effective slice
gum pallets in to the cylinder for control
weight about 148 g after 1st filling step
Change a new bush
Inside for prevent
pallets gum
Slip
Reduce the vibration of filler
by adjust the air cylinder

36. Action v: Reduce the variation of checker weight
Air contact in checker weigh
:Mock up new design protective air
condition fore to checker weigh
cause of if more reject at M/C it
effect operator increase setting
point weigh at filler head
Before improve variation +/- 0.22-3 g
After improve variation +/- 0.01-0.05g

37. Action vi: Study other option to reduce with Eng. team
Option:1 Need to change shape of rubber for control the pallet in pallet rail
Not good cause of many pallets inside rail
Make the new rubber for control 1 roll
If more 1 roll of pallets
it potential to 2nd filling
over setting target

38. Action vi: Study other option to reduce with Eng. team
Option:2 Need to change shape of rail for control pallet inside one roll
If we change the rail a new shape and more length team think to reduce the pallets inside to one roll
Or
current
new
new

39. Action vi: Study other option to reduce with Eng. team
Option:3 Need add the air cylinder for automatic cleaning
The cylinder inject the air about 5-6 bar to automatic cleaning for reduce the variation of load cell

40. Action vi: Study other option to reduce with Eng. team
Option:4 Additional counter sensor and PLC unit to control 2 nd filling
Current Method
1st filling control at 148-149 g
by change the cylinder size
Signal of load cell sent the massage
to open the vibration unit On
Vibration unit running filling
and stop when weight
was over setting 150 g
Some head was over fill
cause of no timing, so the vibrator
didn't know how long time to stop
2 or 3 sec for suitable
New Method
1st filling control at 148-149 g
by change the cylinder size
Signal of load cell sent to
PLC control
PLC calculate and
sent massage to vibrator
Add the counter sensor
The vibrator on 2-3 sec
depend on weight
still left for control
add 1-2 pallets by feed
back from counter sensor
to control

41. Action vi:New high speed counter machine
Production criteria for M/C
1. Can count pallets about 90,000-120,000 pallets per
2.
3.
4.
5.
6.
7.
8.
minute
Can count accuracy + 0-0.5 pallets
Easy production with 1 operator control only
Can easy cleaning for change over finish in 1 hr.
Don’t make the defect of cracking pallets when filling
In standard food safety and hygienic engineering
Size of M/C can replace in current filler or minor
modification
M/C efficiency should be 95%

43. Process Mapping and Texture Analysis
of Soft Chew
Soft chew is the new technology to be installed at this plant.
Project Sweet is the reconfiguration of the ANZ Candy
business. The project was approved in May 2007 & formally
announced to the business in October
Project Sweet involves three main themes:
 ANZ portfolio harmonisation
 SKU rationalisation
 Reduction in manufacturing complexity – closure of
Avondale and Notting Hill sites

44. Objective
•To understand project management
•To understand the complete process of Soft Chew
•To deal with the process parameters
•To understand Texture and do instrumental texture
analysis

45. Soft Candy
Soft Candies are Low Boiled Candies with residual moisture of
6-10%.
Main raw materials for soft candies are Sugar, Corn Syrup
(Glucose), Vegetable Fat and Emulsifier.
There are three types of soft chew to be manufactured in the
Ladkrabang Plant:
TNCC (Black Currant, Raspberry, Orange, Lemon,
Strawberry)
Fruit Burst (Wildberry, Orange, Banana, Lemon & Lime,
Strawberry)
Minties.
There are two types of wrapping, square and twist which will
be finally packed in bags and sticks.

46. Initial Process Flow of Soft Chew Candy

47. Problems occurred in the trial run:
• The temperature and the moisture at the cooking section was
•
•
•
•
•
•
more than desired.
The adjustment of the dosing unit was done manually.
The sheet thickness at cooling drum was more than required.
The cooling drum temperature was too less which resulted in
the hard candy mass which was not easily pulled as its
temperature was around 25-30◦C.
The pulling was not proper because of low temperature and
hardness of the mass.
As the pulling table was made of Teflon, so during the run
Teflon was sticking in the candy mass.
The pulling table had a chiller water system which was not
needed for pulling.

48. Continue..
• The temperature and RH of the room was fluctuating.
• The mass after pulling required at least 45-50 mins for graining
•
•
•
•
•
•
so the conveyor belt system was not used.
The cutter was not in use.
Once the cutter was used it took almost half day for cleaning
since the mass was too sticky.
The ropes from the extruder were not of the proper shape and
size as it got swelled up after coming out from the cooling
tunnel.
The cut and wrap machine was not working proper.
The ropes were twisting in the cooling tunnel.
It was difficult to make the process flow continuous.

49. Continue..
• Talcum is used before cut and wrap machine so that the rope
does not sticks to the packing machine but talcum sticks to the
final product and the surface of the product has white particles
on it.
Reasons for the problems:
• The main problems were due to the temperature and moisture
content. More the moisture more was the stickiness in the
candy.
• If chiller water is used in the pulling table, there is tendency of
moisture to settle on the table and if it is not used the table
becomes hot.
• Graining was the most important parameter.

50. Continue..
• Improper and fluctuating room temperature and relative
humidity causes improper graining. If this drops beyond a
certain level, the tendency of moisture loss will increase.
• The rope after the extruder will be of proper size, shape and
texture only if it is properly grained.
• Stickiness is one of the most important problems which need to
be reduced.

51. Solutions Recommended:
The temperature of the cooling drum is decreased.
Change the pulling table from Teflon to stainless steel as the
material will not stick on it.
The Dosing & Mixing system has been calibrated and works
well for the various flavors / fruit juices and colour solutions.
But we lose 2 hours each time to clean the system. We have to
develop an online change over mechanism to remove the
cleaning requirements in between TNCC flavors and in
between Fruit burst flavours.
The pre-extruder is required for the proper quality of the candy
and the performance of cut and wrap machine as one time
extrusion through the co-extruder does not give proper results.

52. Continue..
The chiller water is not used at the pulling table. Instead of this
there are several other possibilities:
Use tower water continuous at ambient temperature of
around 35 to 40◦C
Don’t use the continuous supply of chill water i.e.
continuous on and of the supply by the operator.
Have a thin sheet of Teflon if the table is changed from
Teflon to steel.
The temperature of the room is maintained to about 25◦C and
RH to about 48 to 50%.
There should be some arrangement of hot water at the cutter so
that the cleaning is proper and takes place fast.

53. Contd..
The conveyor belt can be changed or some other options
should be considered to complete the graining.
The product after the pulling should be kept at different
conditions to check which the best graining process is.
The mass cannot be pulled longer than 6 minutes because
The mass collapses on the table and is no more held by the
hooks essentially no more pulling happens.
Addition of milled sugar on the pulling machine changes the
texture of the product and it becomes grainy.
The talcum used should be replaced by some other material.

54. Different Options For Graining:
Option 1
The mass after pulling was kept for graining in three condition:
Air condition room
Atmospheric condition
Hot cabinet

55. Result:
The best graining was that after the hot cabinet
It took almost 1 hr 20 min for the materials after pulling to
go to the extruder.
The graining in the air condition room was also good but
took a lot of time.
The product took almost 2 hrs to grain in the atmospheric
condition

56. Option 2:
In this option the material was extruded two times in the co-
extruder after the aging.
First the material was kept in AC room for around 30 minutes
at 25-28◦C and RH of around 50-55%.
It is then extruded once at a temperature of around 30◦C, and
then after passing through cooling tunnel.

57. Result:
The rope after extruding 2nd time was of a fine texture and
smooth and the cut and wrap machine also showed better
results.
In this method the cut and wrap machine was giving 65%
performance and texture and weight of wrapped candy was
good.
This design did not matched at all to the original process
design.
One more problem was the hot cabinet

58. Option 3:
This option was similar to the option 2.
The only difference was that after extruding once it was kept in
the open tubs for some time rather than cooling tunnel before
sending it to the hot cabinet.
When the system is extruded two times, complete graining
takes place since graining is initiated by proper extrusion.

59. Result:
The product obtained from this option also satisfied the
desired conditions and was of good quality but the aging
time was more than an hour.
The product from the above two options were similar but
the problems were hot cabinet and different with the
original plan.
As the process is not continuous, the number of heads has
increased.

60. Option 4:
This option is also similar to the previous one but the aging
time was increased to one hour.
Instead of keeping the material in the hot cabinet it was kept in
AC room at 25-26◦C for some time and then extruded and
passed through cooling tunnel.

61. Result:
This option also provided with satisfactory result and the
problems related to hot cabinet was also solved.
The texture and weight of product was also good but cut
and wrap machine was not giving proper performance.
the only problem was to make the system continuous and
use only one extruder.
The aging time was also coming to about 2 hours which
needs to be reduced for the proper flow of the process.
As the whole plant is designed keeping in mind the
continuity of the process so changing the design will cause
increased investment as well as delay in the commercial
run.

62. Option 5:
 Since two times extruder was not satisfying all the needs, so pre extruder
was taken into consideration
 As aging time was not coming to be less than 1 hour in any of the above
case and 30 to 45 minutes was also required between the 1st and the 2nd
extrusion so a total of at least 2 hours was reserved for aging.
 In this we have increased the initial aging time to 1:15 to 1:20 hrs.
 After this the grained mass is passed through the pre extruder where it is
extruded into thin sheets.

63. Contd…
It is then passed through the conveyor to the rove cutter and then to
the co-extruder and cooling tunnel.
The conveyor takes approximately 6 minutes to transfer the material
from pre extruder to the cutter and 1 min from cutter to extruder.
Result :
 For some of the flavors the product was of fine texture but same
process was not applicable for few flavors.
 Since the candy mass is sticky after the pre extruder, it got stuck
in the cutter and it was difficult to operate.
 the change over and cleaning time is long of approximately 3 to 4
hrs.
 This option was good and the final product was also good in
texture and weight but there was some problem in the
performance of cut and wrap machine.

64. Option 6:
The rove cutter is removed because of the problems discussed
earlier.
There were some more options similar to this one:
Instead of the conveyor the candy mass is kept in AC room for
30 minutes.
Instead of the conveyor the candy mass is kept in AC room for
30 minutes and then kept in the oven after first time extrusion
at around 35◦C for 30 min. and then again passed through the
extruder.
But these two options were not better than the one showed in the
figure.

65. Result:
This was by far the best option.
The cut and wrap machine was also giving better
performance and the rope was smooth and not much hard.
 The pre extruder was installed near to the pulling table.
The number of heads was also reduced as the material was
carried to the extruder by the conveyor belt.
Overall a better product with not much change in the overall
process, except the installation of the pre extruder which
was initially bought from the gum plant.

66. Results of the trial runs:
The problem of continuity of the process still remains because
aging is necessary and it requires minimum of 1 hour 20
minutes.
The initial process design fails at this step and the conveyor
and cutter system are not used significantly.
the chiller water arrangement is removed from the pulling table
and the pulling table is changed to the stainless steel from
black Teflon.
The best option after considering all was option 5 as only pre
extruder installation was the change in the process and the
product satisfied all the tests including texture, moisture, and
acidity.
Two times passing through extruder was also a good option but
for that the conveyor belt should be removed and a new coextruder was to be installed which was not fitting the plant
layout and also the number of heads in this process was more.

67. TEXTURE ANALYSIS
OBJECTIVES
Comparison of the trial products, S&T product, and
original Avondale product.
To compare the texture of candy mass at different steps
in the process.
To match the objectives of the trial run with the
required product texture.

68. What do we mean
by texture ?
Texture can be regarded as a manifestation of the
rheological properties of a food.
It is an important attribute in that it affects processing
and handling, influences food habits, and affects shelf-life
and consumer acceptance of foods.
Characterization of food texture commonly falls into two
main groups
 based on sensory, and
instrumental methods of analysis.

69. Textural Properties
Hardness: resistance to deformation
Toughness:
Adhesiveness
Stickiness

70. Texture analysis in lab:
Texture of the candy was analysed for all the runs and it was
compared with the standard product from Avondale and that
prepared in the S&T lab.
The graphs of all the flavours were compared after different
steps in the processes and then the final candy was compared
with the standards.
The different steps were:
After pull
After one time extrusion under different conditions
After two time extrusion under different conditions
After pre extruder
After the wrapping of the candy
After the final graining i.e. minimum 3 days after wrapping

71. Texture Analysis of all the 5 flavours of TNCC
The products from Avondale, Plant Trial Run and S&T
were kept at same temperature.
5 samples were taken of each flavour
All the samples taken from Plant trial were kept for at
least 6 days before texture analysis.
The black line in the graph represents Avondale
product
The red line represents S&T product
The texture was analyzed for different flavors and the
results for almost all the flavors was same.

72. FLAVOUR: LEMON
Force (kg)
3.0
2.5
2.0
1
.5
1
.0
0.5
0.0
-0.5
-1
.0
-1
.5
-2.0
-2.5
-3.0
0
1
2
3
4
5
6
Time (sec)
TNLM_AVN_AVG
TNLM_TRIAL_DEC9_AVG
TNLM_ST_AVG

73. Results..
The products in the trial run are soft and less sticky than that of
S&T and Avondale product. Other properties toughness and
adhesiveness is also less.
The product is formed using two times co-extruder
The product formed in the S&T lab varies greatly with the
others i.e. Avondale and plant trial run.
The adhesiveness and stickiness of the trial run product is same
as that of Avondale.
The product formed is of good quality