Parle Products is India's largest manufacturer of biscuits and confectioneries with over 80 years of operations. They produce many popular biscuit and snack brands like Parle-G, Hide and Seek, Krackjack, and Monaco. The document outlines Parle's production process which involves receiving raw materials, mixing ingredients, moulding dough, baking biscuits in large oven tunnels, cooling, packaging, and dispatching finished products. Quality checks are performed throughout and defective biscuits are recycled back into the production process to minimize waste.

1. PARLE PRODUCTS

2. INTRODUCTION
• Largest Manufacturer’s of Biscuits & Confectionaries almost 80years.
• Parle itself symbolizes quality, nutrition & great taste.
• Most of Parle product are Market Leaders.
• Available Everywhere.
• Beacon of faith & trust for the consumers.
• Great strength is extremely widespread distribution network.

3. Parle Product’s
Biscuits.. Confectionery.. Snacks
 Parle-G
 Krackjack
 Hide n Seek
 Magix
 Monaco
 Kreamz
 Milk Shakti
 Parle Marie
 Melody
 Kismi Gold
 Mango bite
 Kacha Mango bite
 Orange Candy
 Poppins
 Kismi Toffee
 Mazelo
 Parle Wafers
 Musst Bite
 Jeffs
 Cheesling
 Musst tix n Musst
 Sixer
 Sixer Zeera
 Full Toss

4. Mr. Nishikant Pathak
(Education Co-ordinator,
Parle Products Pvt Ltd.)
Mr. Nadeem Ansari (Sales
Executive , Parle )

5. • Skim Milk Powder
• Leaving Agents
• Salt
• Emulsifiers
• SMBS
• Flavors
• Citric Acid
• Wheat Flour (Maida)
• Fat (RBD Palm Oil)]
• Sugar
• Invert Sugar Syrup
• Water
INGREDIENTS
Major Minor

6. • Maida– Soft wheat flour is required, as it gives more tender biscuit than hard
wheat flour.
• RBD Palm oil–
 Helps in reducing toughness of dough,
 Provide sensory (moistness, shortness, crispness & crunchiness)
 Protects Flavor
• Sugar– Quantity and Crystal Size of Sugar has big influence on biscuit texture
and dimension. Improves the flavor and makes biscuit hard
• Invert Sugar Syrup– Helps to give color, flavor & decrease crystallization.
• Water– One of important ingredient used in almost all processes.

7. • Skim Milk Powder– To subtle the flavor and textural improvements and to aid
surface colouring.
• Leaving Agents
 Ammonia Bi-Carbonate
 Sodium Bi-Carbonate
 Salt
 Emulsifiers
Lecithin or Finamul
 Sodium Meta Bi-Sulphate (SMBS)
 Flavors
 Citric Acid

8. PRODUCTION PROCESS
Store
Receiving of Raw Materials
Quality Check Rejected
Unloading of R.M.
Inputs

9. Raw Material
Maida Dumping & sifting
Mixing Fat
Sugar
(Grinded)
Other Ingredients
Moulding
Proofing
Baking
Process

10. Cooling in Conveyors
Passes by Metal Detector
Packaging
Storage
Dispatch
Baking
Coloring

11. STEPHAN MIXER
MOULDING
OVEN
COOLING
CONVEYOR
STALKING TABLE
CURVE
PLATE
CURVE
PLATE
MULTIPACK
MACHINE
SEALING
MACHINEBOX
TAPPING
DIVERSION
BELT
CONVEYOR
BELT
DISPATCH
SECTION
PROCESS LAYOUT

12. PROCESSES

13. Maida dumping and sifting
 Done by 2 methods – Automatic
and Manual
 In Automatic, Maida from dosing
tank is transferred to mixer
pneumatically.
 In Manual, Maida is transferred
to maida sifter by screw
conveyor and then feeding in
the mixer manually.
 Now Automatic system is used
Screw Conveyor
Dosing Tank

14. Sugar grinder
 Sugar bags are unloaded &
passed through metal
detectors to remove any
metal particles.
 Sugar is transferred to
grinder through screw
conveyor.
 Grinded sugar is stored in
Service Tank & from there it
is send to mixer.
Service Tank

15. Pumping of Fat
 Fat stored in the Silos is
pumped at a temperature
of 45`c.
 Fat is mixed with Lecithin
(an Emulsifying agent).
 Mixture of Fat & Lecithin
is added to Liquid vessels
from where it is added to
the mixer for dough
preparation.
Silos
Liquid Vessel

16. Stephan mixer
 Material mixed in the
vessels are brought
together in mixer and
stirred for sometime.
 After that, the mixture is
passed to Stephan mixer,
where it is mixed by a
speed motor for 1-1.5 mins.
Temperatures specification at
mixing sections
• Water – 15-20`C
• Sugar Syrup – 30`C
• Powder (Sugar + Flour)– 30`C
• RBD Palm Oil – 45-50`C
• Dough Temp. – 28-32`C
Stephan Mixer

17. METAL DETECTOR
• Dough after cutting is
passed through metal
detector, which is just above
dough conveyor; it can
detect all types of metallic
materials.
• Many detectors are placed
through the complete
system for checking of
metal components.

18. ROTARY MOULDER
31 rows present on the die roll.
12 moulds in a row.

19. OVEN
• 240 feet long oven.
• Consist of 7 chambers.
• 7 chambers are formed of 3 zones.
 Puffing Zone
 Baking Zone
 Coloring Zone
• For baking, LPG or Propane direct gas is fired inside the oven.
• Oven consists of wire band moving inside the oven.
• Temperature set is different in each zone.

20. • Puffing zone (Zone 1 to 3 )
The leavening agents act a major role in this zone. Steam and volatile
gases do rise & increase the volume of the biscuit. This gives a porous
texture by the formation of puffs in the biscuit.
• Baking zone (Zone 4 & 5 )
This is the zone where the biscuits actually get baked. The temperature
of this zone is between 220-320`C. the moisture get evaporated in this
zone and biscuit get baked from inside.
• Coloring zone (Zone 7 & 8 )
This is the zone where the color of the biscuit is attained. The
temperature of this reaction is less than that of the baking zone.
The graph of temperature inside the oven is parabolic i.e. in initial zone temp. is
less, then in middle zone temp. goes to the peak point and in the last zone temp.
reduces again.
Time required to pass through oven is approximately 3mins.

21. Cooling conveyor
 It is made up of Convase and
biscuits are cooled naturally
on the conveyor.
 Length of the conveyor belt is
350feets.
 Metal detectors are placed
just above the conveyors for
detection of any metal
component present in biscuit.
 Time required for the flow of
biscuits is approximately 6
mins.
 Biscuits move 4 rounds of
cooling conveyor for cooling

22. PACKAGING

23. Packaging consist of three sections
1. Stacking of Biscuits
2. Packaging
3. Dispatch

24. STACKING
• Aligns the biscuits in rows and these rows of biscuits move with
stacker table belt.
• A brush roll is fitted just above the stacker belt to control the
movement of biscuits.
• Operator at he stacker checks the biscuit quality and rejects the
defective.
• These biscuits are sent to packaging machine manually.

25. PACKAGING MACHINE
• Biscuits are packed in various sizes.
• Machines automatically wrap the wrappers
around the biscuits.
• Sealing is done with the roller heaters.
• Some heaters are used for side sealing and
some are used for cross sealing.
• Packaging material used is BOPP (Bioxyl
Oriented Polypropylene).
• After packing the packets are sealed in poly
bags and they are packed into cartoon
boxes, these boxes are sealed and batch
number is printed on them

26.  Biscuits packed in boxes are
moved through conveyors and cam
roller belts to the storage room or
the loading of the truck.
 Storage of goods is also done
automatically.

27. DISPATCHING
 The biscuits packed in a C-boxes are collected on a pallet in the
B.S.R.(Bounded Stock Room) section.
 These pallets are carried by a forklift.
 These boxes are loaded in truck and transported to various situated at
different locations.

28. • In case of poor finishing or broken or burned out
biscuits, it is kept aside in a different container.
• These biscuits are crushed to powder form again
and are used again.
• 5% of crushed biscuits is used in the new
mixture of biscuits.
• No Wastages.

29. CAPACITY UTILIZATION
• Capacity : 3000 tonnes of Biscuits/month
100 tonnes of Biscuits/day
• Capacity Utilization of 85% Approximately